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Three types of textile fabric waste, namely Kevlar, Nomex, and Cordura Nylon, were investigated in this study. The effects of the fiber parameters: volume fraction (0.1%, 0.3%, and 0.5%), length (6, 12, and 24 mm), and use of 1D fiber (width of 0) versus 2D woven fabric fiber (width of 3 and 6 mm) on strength properties, flowability, and shrinkage were studied to determine the optimum textile parameters. The pore structure, microstructure, and fiber-matrix interfacial properties of the optimised mixtures were then characterized by means of X-ray micro-CT, SEM, and nanoindentation at 7, 28, and 90 days. Results showed that the optimized parameters for three types of fabric fibers are 1D fiber (width of 0), length of 12 mm, and volume fraction of 0.3%. This optimized design provided an enhancement of strength and shrinkage resistance. Pore refinement was pronounced in the case of hydrophilic Kevlar and Nomex fibers. However, this also correlates to inferior performance in shrinkage resistance of mortar compared to hydrophobic Cordura Nylon. The fiber-matrix ITZ thickness was dependent on fiber size, while the wettability of fibers (i.e., hydrophobicity or hydrophilicity) was observed to affect the phase distribution in the vicinity of the fiber surface. Furthermore, a large volumetric proportion of the structure is porous in nature (more than 50%) in the region of the fiber-matrix interface after 7 days. With the increment of curing age, the microstructure at the fiber interface becomes denser due to the hydration of the clinker phase facilitating the growth of CSH and CH phases. [ABSTRACT FROM AUTHOR]

In this study, carpet waste fibers--namely, polypropylene (PP) and polytrimethylene terephthalate (PTT) in the form of mono microfibers and hybrid combinations--were studied. The optimization of mono fiber parameters for fiber content (0.1, 0.3, and 0.5%) and length (6, 12, and 24 mm [0.236, 0.742, and 0.945 in.]) were conducted to achieve the optimum strength properties and minimize drying shrinkage. The microstructure, pore structure, and fiber-matrix interfacial properties of the optimized samples were characterized at 7, 28, and 90 days by means of scanning electron microscopy (SEM), X-ray micro-computed tomography (CT), and nanoindentation. The research data revealed that the inclusion of either the optimized mono PP fiber (υf = 0.5% and l = 12 mm [0.472 in.]) or PTT fiber (υf = 0.1% and l = 12 mm [0.472 in.]) improved the compressive strength of 4.3% and 16.1%, and the flexural strength by 11.5% and 9.2% at 28 days, respectively. Hybrid carpet fibers (0.4% PP + 0.1% PTT) provided a greater enhancement in compressive strength of 6.6%, and flexural strength by 13% at 28 days. Drying shrinkage mitigation of mortar over 120 days was recorded as 18.4, 22.3, and 25.8%, corresponding to the addition of 0.5% PP fibers, 0.1% PTT fibers, and hybrid PP/PTT carpet fibers. A pore-refining effect was also observed for mortars with 0.5% PP and hybrid PP/PTT carpet microfibers. The SEM images indicated that the trilobal cross-sectional shape of PTT carpet fibers had a stronger anchoring effect with cement hydrates than the rounded shape of PP carpet fibers. Nanoindentation identified the thickness of the fiber-matrix interfacial transition zone (ITZ) as approximately 15 µm (5.9 × 10-4 in.) for both mono PP and PTT fibers. Approximately 50% of the phases in the vicinity of the fiber-matrix interface comprised a porous structure at 7 days. However, the hydration of clinker over the 90-day period promoted the formation of calcium-silicate-hydrate (C-S-H) and portlandite to form a dense microstructure. [ABSTRACT FROM AUTHOR]

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]

Geopolymer aggregate (GPA) is a novel coarse aggregate synthesized from low-calcium fly ash with a highly alkaline activator. It is also classified as a lightweight aggregate, having a density of 1709 kg/m³ (106.7 lb/ft3). This paper reports the findings of the detailed investigation of mechanical properties of GPA concrete, which was observed up to a period of 1 year. The characteristics of GPA concrete were benchmarked against conventional basalt aggregate concrete. Compressive, flexural, and splitting tensile strengths, elastic modulus, and Poisson's ratio of GPA concrete ranged from 42.1 to 50.81 MPa (6.1 to 7.37 ksi), 4.75 to 5.27 MPa (0.69 to 0.76 ksi), 3.02 to 3.66 MPa (0.44 to 0.53 ksi), 20 to 20.5 GPa (2900 to 2973 ksi), and 0.13 to 0.11, respectively within a 90- to 365-day period. The correlations between existing concrete standards and major mechanical properties of GPA concrete are discussed. Relationships are developed between compressive strength and mechanical properties including flexural strength, splitting tensile strength, and elastic modulus using statistical regression analysis. The suitability of using the existing relationships in Australian standards and American Concrete Institute codes for GPA concrete are critically examined. In addition, the microstructure of GPA concrete was examined using scanning electron microscopy (SEM) imaging and microhardness testing. The thickness of the interfacial transition zone (ITZ) is estimated to be 55, 50, and 45 µm (21.65 x 10-4, 19.68 x 10-4, and 17.72 x 10-4 in.) at 28, 90, and 365 days, respectively. Overall, the observations of this study verify the potential of using GPA concrete in various structural applications, making it a viable and sustainable alternative to conventional aggregate concrete. [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]

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]

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]

Geopolymer is a sustainable construction material produced by the activation of fly ash using a high concentration alkali to initiate a polymerisation reaction. A key parameter in determining the potential adoption of geopolymer concrete in the construction industry is the long term durability of the material. To determine the durability characteristics a detailed investigation of the permeation properties of four different fly ash geopolymer concretes was carried out up to one year of age. An improvement in the durability properties is observed for all geopolymer concretes with time. This is attributed to an on-going geopolymerization which results in continuing gel formation leading to a more densely packed microstructure, with an associated reduction in meso-pores and macro-pores. The packing density coupled, with the pore size distribution, were observed to determine the permeation and diffusion characteristics of the concrete. The increased in meso-pores represents the increase in the gel of the matrix and in turn this affect the increase of water absorption. On the other hand, a high quantity of macro-pores leads to an increase in the water and air permeability of geopolymer concrete. A large quantity of coarse particles in fly ash results in an uneven gel distribution which reduces pore-filling ability, while the presence of a high quantity of CaO was observed to contribute to a densely packed microstructure. Notably the initial chloride diffusion coefficients are analogous to those observed in Portland and blended cement concretes and also decrease with the age in a similar manner. [ABSTRACT FROM AUTHOR]

• Hydrophilic fabric fibres refine the pore structure of cementitious matrices. • Hybrid hydrophobic and hydrophilic fibres counterbalance the pore-refining effects. • Fabric waste fibres suppress the crack propagation and mitigate the quantity of cracks. • Hybrid fabric fibres significantly reduces the shrinkage of cementitious composites. • Blended fabric waste fibres can improve strength properties of cement-based materials. In this study, the strength properties, shrinkage and microstructures of mortar incorporating blended fabric fibres were characterised via X-ray micro CT and nanoindentation. Three different hybrid recycled fabric fibres, namely Kevlar/Nomex, Kevlar/Nylon and Nomex/Nylon fibres were investigated at three different blend ratios (2:1, 1:1, and 1:2). The fibre content was maintained at 0.3 % for all mixes. The findings indicated that the optimum blend ratio for hybrid fabric fibres is 1:1. At this optimum fibre blend ratio, an enhancement by 2.7 %, 4.8 % and 5.9 % in compressive strength, together with 9.8 %, 12 % and 13.4 % in flexural strength of mortar are recorded, corresponding to the inclusion of hybrid Nomex/Nylon, Kevlar/Nomex and Kevlar/Nylon fibres respectively. Kevlar/Nomex fibres display no effect in drying shrinkage mitigation, irrespective of blend ratios. In contrast, Kevlar/Nylon and Nomex/Nylon fibres result in reducing 180-day shrinkage rates by up to 13.9 % and 11 % respectively. The hybrid fabric fibres were found to refine the pore network, especially the highly hydrophilic Kevlar/Nomex fibres. Also, an increase in curing days from 7 to 90 days densifies the microstructure near the fibre-matrix interface due to the growth of hydration products (LD/HD C S H and CH). These research findings can open the pathway for utilising textile waste in landfill as reinforcing members for cementitious matrices toward sustainable building and construction. [ABSTRACT FROM AUTHOR]

• The inclusion of PP, PE, and PVA fibres increases total porosity of cementitious matrices. • Hydrophilic fibres tend to reduce the average pore size of cementitious matrices. • Pore refinement effect is pronounced with the inclusion of microfibres. • Thermal expansion of fibres initiates cracks and releases pressure at elevated temperatures. • High melting viscosity of HDPE inhibits vapour transport and show less spalling mitigation. Synthetic fibres such as polypropylene (PP), polyvinyl alcohol (PVA), and polyethylene (PE) in both virgin and recycled forms have been widely employed in cementitious composites. Apart from providing bridging action for absorbing stress-induced energy, the addition of polymeric fibres also changes the pore systems in the microstructure of cementitious materials. This paper reviews the microstructure changes of cementitious composite incorporating these three polymeric fibres under both ambient and high-temperature condition. The microstructure of polymeric fibre reinforced concrete is characterised by higher porosity than plain concrete. The use of hydrophilic PVA fibres with microfibres induces pore-refining effects. At elevated temperature PP, PVA and low-density PE (LDPE) exhibit good spalling resistance in concrete due to the formation of microcracks and empty channels left by melted fibre. However, high-density PE (HDPE) fibre is ineffective in mitigating the increased vapour pressure in concrete due to a low coefficient of thermal expansion and high viscosity. Furthermore, to achieve well-balanced interfacial properties, physical/chemical surface modification is necessitated. The introduction of reactive functional groups into the polymer chain of hydrophobic PP and PE fibre significantly enhance fibre-matrix interaction in strengthening interfacial properties with cement paste. Whereas, neutralising hydroxyl functional groups in the PVA polymer chain counteracts extreme delamination or fibrillation of polar PVA fibre when they interact with the cement matrix. With surface modification, the possibility of premature rupture of PVA fibre can be minimised, while improving the transfer of stress-induced energy between the cement matrix and the fibre. [ABSTRACT FROM AUTHOR]