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The long-term creep and shrinkage behaviour of two High-Volume Fly Ash (HVFA) concretes incorporating nano silica with 65% and 80% replacement of cement has been investigated. This comprised a detailed analysis of the microstructure, pore structure and chemistry of the two HVFA systems up to a period of 450 days. The compressive strength and modulus of elasticity of HVFA-65 concrete increased from 32 to 73 MPa and 30.3 to 40.5 GPa, respectively between 7 and 450 days. The HVFA-80 concrete achieved compressive strength values of 22 and 71 MPa and elastic modulus values of 28.9 and 37 GPa. After a total loading period of 450 days, HVFA-65 and HVFA-80 concretes displayed creep parameters, which were significantly below the values predicted by AS 3600, ACI 209 and CEB-FIP standard model equations. After a total drying period of 450 days 28-day cured specimens showed significantly reduced shrinkage compared to 7-day cured specimens. On the other hand, HVFA-80 concrete displayed higher shrinkage compared to the HVFA-65 specimens throughout the period. All specimens except for 7-day cured HVFA-80 concrete were within the maximum permissible shrinkage of 800 microns recommended for Australian construction practices. HVFA-65 concrete showed a denser microstructure and a stronger, better packed interfacial transition zone (ITZ) compared to HVFA-80 at all ages. The XRD and FTIR analysis data identified the formation of hydration products including C-S-H and C-A-S-H which contributed towards both the strength gain as well as the creep and shrinkage properties displayed by the HVFA concrete by minimizing the total porosity and pore size. [ABSTRACT FROM AUTHOR]

Production of alkali-activated binders is a developing research field that utilizes industrial/agricultural by-products and solid waste for the development of sustainable concrete. This paper comprehensively reviews the literature relating to rice husk ash (RHA)–based alkali-activated binders incorporating fly ash (low/high calcium) and blast furnace slag. The literature demonstrates that the properties of raw material significantly influence the formation of the alkali-activated gel matrix. Every precursor (low/high calcium fly ash and slag) that is used to develop alkali-activated binders with RHA have their own reaction mechanism dependant on their specific chemical composition. Hence the incorporation of RHA influences each binder in a unique way depending upon the alkali activation process and reaction mechanisms. The incorporation of RHA, in the range 5%–15%, with blended slag alkali activated binders, yields better compressive strength, when compared with RHA blended with fly ash (low/high calcium). The review presented in this paper is very useful to understand the behavior of alkali-activated binders incorporating RHA and in advancing the research into the successful application of RHA as a binder for alkali-activated materials. [ABSTRACT FROM AUTHOR]

The potential application of alkali-activated material (AAM) as an alternative binder in concrete to reduce the environmental impact of cement production has now been established. However, as the production and availability of the primarily utilized waste materials, such as fly Ash and blast furnace slag, decrease, it is necessary to identify alternative materials. One such material is clay, which contains aluminosilicates and is abundantly available across the world. However, the reactivity of untreated low-grade clay can be low. Calcination can be used to activate clay, but this can consume significant energy. To address this issue, this paper reports the investigation of two calcination methodologies, utilizing low-temperature and high-temperature regimes of different durations, namely 24 h heating at 120 °C and 5 h at 750 °C and, and the results are compared with those of the mechanical performance of the AAM produced with untreated low-grade clay. The investigation used two alkali dosages, 10% and 15%, with an alkali modulus varying from 1.0 to 1.75. An increase in strength was observed with calcination of the clay at both 120 and 750 °C compared to untreated clay. Specimens with a dosage of 10% showed enhanced performance compared to those with 15%, with Alkali Modulus (AM) of 1.0 giving the optimal strength at 28 days for both dosages. The strengths achieved were in the range 10 to 20 MPa, suitable for use as concrete masonry brick. The conversion of Al (IV) is identified as the primary factor for the observed increase in strength. [ABSTRACT FROM AUTHOR]

An investigation has been conducted to identify the reaction mechanism and compressive strength of geopolymer made from brown coal fly ash from two locations at Yallourn power station in Australia. The Yallourn-1 (Y1) ash has completed the storage period within the pond, whereas Yallourn-2 (Y2) ash has been stored in the pond for a short period of time. Compressive strength of Y1 geopolymer increased from 12.63 MPa (1.83 ksi) at 7 days to 13.62 MPa (1.98 ksi) at 28 days and 15.90 MPa (2.31 ksi) by 90 days, whereas Y2 achieved 13.26 MPa (1.92 ksi) at 7 days but reduced in strength to 8.55 MPa (1.24 ksi) by 28 days, followed by an increase in strength to 14.00 MPa (2.03 ksi) by 90 days. The low strengths observed is attributed to the low of alumina content of the Yallourn ash, coupled with the higher unburnt carbon content. [ABSTRACT FROM AUTHOR]

Quarry aggregate reserves are depleting rapidly within Australia and the rest of the world due to an increasing demand for aggregates driven by expansion in construction. The annual production of premix concrete in Australia is approximately 30 million cubic meters, while 3–5% of concrete delivered to site remains unused and is disposed of in landfill or crushing plants. The production of coarse aggregates using this waste concrete is potentially a sustainable approach to reduce environmental and economic impact. A testing program has been conducted to investigate mechanical performance and permeation characteristics of concrete produced using a novel manufactured coarse aggregate recycled directly from fresh premix concrete. The recycled coarse aggregate (RCA) concrete satisfied the specified 28-day design strength of 25 MPa and 40 MPa at 28 days and a mean compressive strength of 60 MPa at 90 days. Aggregate grading was observed to determine strength development, while low water absorption, low drying shrinkage, and higher packing density indicate that the RCA concrete is a high-quality material with a dense pore structure. The rough fracture surface of the aggregate increased the bond between C-S-H gel matrix and RCA at the interfacial transition zone. Furthermore, a good correlation was observed between compressive strength and all other mechanical properties displayed by the quarried aggregate concrete. The application of design equations as stated in Australian standards were observed to provide a conservative design for RCA concrete structures based on the mechanical properties. [ABSTRACT FROM AUTHOR]

This study investigates low cement quaternary blend HVFA concrete mixes utilizing up to 80% cement replacement using fly ash, hydrated lime and nano-silica. The optimized concrete mixes achieved a compressive strength of 55 MPa and 48 MPa, for HVFA-65 and HVFA-80 concretes, respectively. Additional fly ash and hydrated lime dosage in HVFA concrete increased the rate of hydration of the C3A and C4AF phases but decreased the hydration of the C3S phase. This resulted in lower early age strength development in the HVFA concrete than occurs in PC concrete but significantly higher than for fly ash and hydrated lime alone. The addition of the nano-silica resulted in an increase in C–S–H gel incorporation of tetrahedrally coordinated aluminium (AlIV) into the HVFA concrete and the substitution of Si by Al in the C–S–H gel, leading to an increase in compressive strength in the HVFA concrete. Early age carbonation was increased with a higher of fly ash percentage. However, the reaction products dissolved in the pore water to form calcium bicarbonate with time. [ABSTRACT FROM AUTHOR]

A comprehensive experimental study has been conducted to investigate the geopolymerisation and compressive strength development of mortar made from brown coal fly ash from two separate locations in the storage ponds of an Australian power plant. The specimens gave similar compressive strengths but had significantly different material and performance characteristics despite being from the same storage location. The Loy Yang‒A (LYA) geopolymer mortar demonstrated an approx. 30% strength increase while Loy Yang‒B (LYB) gave an approx. 18% strength drop over the period from 7 and 90 d, though both geopolymer mortars initially achieved a similar 28-d strength of approx. 23 MPa. The LYA ash had almost double the alumina content compared to LYB and a higher proportion of AlVI compared to the LYB. The lower alumina content coupled with the low quantity of AlVI in the ash and its lower conversion to AlVI during geopolymerisation is identified as the primary reason for the reduction in strength observed in the LYB geopolymer. The increase of Q4(3Al) during geopolymerisation and some conversion to Q4(4Al) coordination over time resulted in the increase in the compressive strength observed in the LYA mortar. This strength increase of LYA mortar is further correlated with an increase in Quartz phases coupled with a reduction in the Moganite phase. Formation of sodium carbonate due to atmospheric carbonation of unreacted sodium hydroxide in Loy Yang geopolymer additionally contributed to the strength development of LYA geopolymer. [ABSTRACT FROM AUTHOR]

This study reports the effect of heat curing at 120 °C on the geopolymeric reaction and strength evolution in brown coal fly ash based geopolymer mortar and concrete. Moreover, an examination of this temperature profile of large size geopolymer concrete specimens is also reported. The specimen temperature and size were observed to influence the conversion from the glassy (amorphous) phases to the crystalline phases and the microstructure development of the geopolymer. The temperature profile could be divided into three principal stages which correlated well with the proposed reaction mechanism for class F fly ash geopolymers. The geopolymerisation progressed more rapidly for the mortar specimens than the concrete specimens with 12 to 14 h providing an optimum curing time for the 50 mm mortar cubes and 24 h being the optimum time for the 100 mm concrete cubes. The 50 mm and 100 mm concrete specimens' compressive strengths in excess of 30 MPa could be obtained at 7 days. The structural integrity was not achieved at the center of 200 mm and 300 mm concrete specimens following 24 h curing at 120 °C. Hence, the optimal curing time required to achieve the best compressive strength for brown coal geopolymer was identified as being dependent on the specimen size. [ABSTRACT FROM AUTHOR]

Fly ash geopolymer concrete is a sustainable green construction material that has outstanding mechanical performance and is a low-energy material with a low carbon footprint. In this study, a detailed investigation of the long-term creep and drying shrinkage of three different 100% fly ash geopolymer concretes was carried out up to 1 year of age. Two geopolymers, produced from Gladstone and Pt. Augusta fly ashes, achieved approximately 700 microstrain at the end of 1 year--equivalent to the total creep strain displayed by portland cement (PC) concrete. Moreover, both geopolymer concretes displayed a lower creep coefficient than PC concrete. Hence, AS 3600 or the CEB-FIP model could be conservatively used to predict creep coefficient for two geopolymers. However, the Tarong fly ash geopolymer concrete differed significantly from the other geopolymers and achieved approximately 1900 microstrain after 1 year. The drying shrinkage of Gladstone and Pt. Augusta geopolymer concretes at 1 year are 175 and 190 microstrain, respectively, while Tarong geopolymer and PC concrete achieved 615 and 475 microstrain, respectively. All the fly ash geopolymer concrete showed lower drying shrinkage than the maximum permitted value recommended by AS3600. Incorporation of calcium-aluminasilicate- hydrate (C-A-S-H) gel with the sodium-alumina-silicatehydrate (N-A-S-H) geopolymeric gel was seen to positively affect the packing density of the gel phase. The degree of uniformity and compactness of aluminosilicate gel matrix together with the macroporosity in the 50 nm to 1 µm range was identified as determining the long-term creep and drying shrinkage of the 100% low-calcium fly ash geopolymer concrete. [ABSTRACT FROM AUTHOR]

The properties and microstructure of a novel manufactured geopolymer coarse aggregate have been investigated. The analysis has included compressive and tensile strengths of concretes made with the manufactured geopolymer coarse aggregate and a comparative natural crushed coarse aggregate. In addition, the microstructure and pore structure development of both concretes at the interfacial transition zone (ITZ) and bulk cement matrix were studied though scanning electron microscopy and X-ray computed tomography. The data showed that the novel geopolymer coarse aggregate satisfied the requirements of Australian Standard AS 2758.1 and is comparable to the natural aggregate. The dry density of the geopolymer aggregate concrete was less than that of the natural aggregate being just over 2000 kg/m3 (124.9 lb/ft3), with a mean 7-day strength in excess of 30 MPa (4.44 ksi) and a mean 28-day compressive strength in excess of 40 MPa (5.8 ksi). Moreover, it showed a 60% reduction in porosity between 7 and 28 days with a wellcompacted and dense ITZ observed at 28 days. In addition, the flexural strength demonstrated a good correlation with compressive strength, comparable to that of the natural aggregate concrete. Overall, the geopolymer investigated in this research shows potential as a lightweight coarse aggregate for concrete, with the additional benefit of reducing the environmental impact of fly ash from coal-fired power generation. [ABSTRACT FROM AUTHOR]

This study evaluates the influence of the elemental distribution in the fly ash particles and their impact on phase formation and compressive strength of five low-calcium fly ash geopolymers. The degree of geopolymerization in each geopolymer system was assessed by FT-IR and solid state 27Al MAS-NMR analysis. The corresponding pore volume changes were investigated by mercury intrusion porosimetry (MIP). The uniformity of the distribution of SiO2 and Al2O3 in the fly ash was observed to directly influence the dissolution of the amorphous surface layer in the initial geopolymerization process and control aluminosilicate gel precipitation and gel-phase creation. The results showed that the higher the uniformity of distribution (coupled with the stable conversion of aluminium from octahedral to tetrahedral coordination), the higher the aluminium amalgamation with silicates. The result of this is the production of a three-dimensional (3-D) polysialatesiloxo (Si-O-Al-O-Si) polymeric gel structure with high rigidity and stability, which in turn results in higher compressive strength. It was also observed that an increase of meso-porosity in geopolymer phase formation coupled with a cumulative pore volume below 1000 nm (3.937 x 10-5 in.) is a good indicator of the degree of geopolymerization. [ABSTRACT FROM AUTHOR]

Geopolymer concrete is a sustainable construction material with the potential to act as a replacement for portland-cement (PC) concretes. A detailed investigation of the mechanical properties of four different fly ash geopolymer concretes was carried out up to 1 year of age. Compressive, flexural, and splitting tensile strengths, elastic modulus, and Poisson's ratio of four geopolymer concretes at 1 year ranged between 28 and 88 MPa (4.06 and 12.76 ksi), 3.92 and 6.3 MPa (0.568 and 0.914 ksi), 1.86 and 4.72 MPa (0.27 and 0.684 ksi), 10.3 and 29 GPa (1493.5 and 4205 ksi), and 0.16 and 0.28, respectively. The results show an increase in performance observed between 90 and 365 days for all concretes depending on the fly ash properties. Tarong displayed the highest increase while Gladstone had the least, although Gladstone did display the best performance throughout. The nature of the gel matrix formed, in terms of uniformity and compactness, was observed to determine the mechanical properties. The nature of the interfacial transition zone formed between coarse aggregate and mortar and its density was observed to govern the tensile strength. An increase in porosity and microcracks was seen to negatively affect the compactness of the gel matrix, which in turn affected the elastic modulus. [ABSTRACT FROM AUTHOR]

A major challenge in the specification of geopolymer mix designs is the variability in the fly ash used and the impact of that variability on the performance of the geopolymer produced. The factors affecting the performance of geopolymers made from a total of five chemically and physically distinct fly ashes are reported. The key factor identified as influencing the strength was the workability, with a flow in the range between 110 ± 5% and 140 ± 5% required for optimal performance. In this flow range, the strength of geopolymer is governed by the specific surface area of precursor fly ash coupled with the quantity of the 10 μm and 20 μm particles. In addition a negative zeta potential of the fly ash was identified as assisting gel formation with the smaller the negative zeta potential of the geopolymer product the more gel formation and high compressive strength observed. [ABSTRACT FROM AUTHOR]

Despite extensive in-depth research into high calcium fly ash geopolymer concretes and a number of proposed methods to calculate the mix proportions, no universally applicable method to determine the mix proportions has been developed. This paper uses an artificial neural network (ANN) machine learning toolbox in a MATLAB programming environment together with a Bayesian regularization algorithm, the Levenberg-Marquardt algorithm and a scaled conjugate gradient algorithm to attain a specified target compressive strength at 28 days. The relationship between the four key parameters, namely water/solid ratio, alkaline activator/binder ratio, Na2SiO3/NaOH ratio and NaOH molarity, and the compressive strength of geopolymer concrete is determined. The geopolymer concrete mix proportions based on the ANN algorithm model and contour plots developed were experimentally validated. Thus, the proposed method can be used to determine mix designs for high calcium fly ash geopolymer concrete in the range 25–45 MPa at 28 days. In addition, the design equations developed using the statistical regression model provide an insight to predict tensile strength and elastic modulus for a given compressive strength. [ABSTRACT FROM AUTHOR]

Geopolymer concrete is a sustainable replacement to the Ordinary Portland Cement (OPC) concrete as it mitigates some of the associated problems of OPC manufacturing such as greenhouse gas emission and natural resource depletion. There has been significant recent research in the design of fly ash-based geopolymer concrete using advanced machine learning techniques which can address some of the problems with classical mix design approaches. However, practical application of geopolymer concrete is limited due to lack of standard mix design procedure. This comprehensive review summarizes the current literature on machine learning methodologies to predict the compressive strength of fly ash-based geopolymer concrete. Firstly, the input parameters used for the machine learning model development are categorized based on feature selection or feature extraction. Secondly, available machine learning approaches are categorized based on analysis methods namely, nonlinear regression, ensemble learning, and evolutionary programming. The effect of hyperparameters on the individual model performance, and model comparison based on the prediction performance are also discussed to identify potentially more suitable model type and hyper parameter ranges. Further, the paper discusses the input variable's sensitivity towards the model performance which provides guidance towards future model developments. Overall, this paper will provide an understanding of the current state of machine learning approaches to predict the compressive strength of geopolymer concrete and the gaps in research for the development of models and achieving the required performance. Hence, the summarized knowledge will be highly beneficial to design prospective research towards sustainable cement-free concrete using fly ash. • Artificial neural networks (ANN) predict geopolymer concrete strength well, offering reliable forecasts for new data. • Support vector machines and random forests offer ANN- like performance, serving as alternatives in machine learning (ML). • The success of ML model relies on proper selection of inputs and tuning hyperparameters for optimal performance. • The chemical, physical, and mineralogical characteristics of fly ash emerge as pivotal input variables in ML models. • Validating models through laboratory experiments is imperative, ensuring generalization for real-world applications. [ABSTRACT FROM AUTHOR]

Many research studies have been conducted during recent years on the topic of geopolymer materials based on the engineering performance of the concrete. What has been missing is the combination of this research in a way that would provide a simple to use design tool for geopolymer concrete as a replacement to concrete based on Portland Cement. This research paper addresses this requirement for developing a standard mix design method for Class F, low calcium fly ash based geopolymer concrete using Multivariate Adaptive Regression Spline (MARS) model. Published geopolymer concrete research data was combined into a database and analysed to give the ratios of water/solid, alkaline activator/fly ash, Na 2 SiO 3 /NaOH, and NaOH molarity. Targeted compressive strengths ranging from 30 MPa to 55 MPa at 28 days were achieved with laboratory experiments, using the proposed MARS mix design methodology. Thus, this tool has the capability to provide a novel approach for the design of geopolymer concrete mixes to achieve the desired compressive strength appropriate for the construction requirement. [ABSTRACT FROM AUTHOR]

• A coupled hydration-thermodynamic model is developed for predicting hydration products and porosity of high-volume fly ash (HVFA) blended cement. • Compressive strength of HVFA binder is computed by multi-scale model using predicted hydration products and porosity. • Porosity of the blended cement increases with fly ash replacement percentage for specific water/binder ratio. • The reaction degree of fly ash and compressive strength show decreasing trend with fly ash replacement percentage. Partial replacement of cement using fly ash, as an environmentally friendly approach, has gained increased attention in construction practice. The realistic prediction of microstructure and mechanical properties of fly ash blended cement paste is therefore noteworthy for many practical applications including selection of construction material and their appraisal of design. In this research work, an integrated framework is proposed and demonstrated for predicting the hydration products and compressive strength of high-volume fly ash binders. The prediction framework is designed to have multiple stages. For computing the hydrates of blended cement paste, a coupled hydration model with thermodynamic modelling is developed. A hierarchical model that captures the development of the paste via multiple levels (from C-S-H globules to blended cement paste) is used subsequently to predict the compressive strength as a function of hydration period. Here, unlike previous works, the formation of C–S–H is realistically modelled by distinguishing it into low- and high-density C–S–H. A series of experiments (including XRD Rietveld analysis, thermo gravimetric analysis, selective dissolution, mercury intrusion porosimetry and compression tests) are performed; hence the predictability of the developed work is assessed by comparing the predicted results with experimental data. A very good agreement is seen between the predicted results (hydration products, pore volume and compressive strength) and experimental results, indicating that the proposed model can be applicable to the high-volume fly ash cement paste to reliably capture the hydrates and compressive strength. It is further noted that with an increase in fly ash replacement ratio, the capillary porosity increases, while the reaction rate and compressive strength decrease. [ABSTRACT FROM AUTHOR]