Investigating the High-Temperature Bonding Performance of Refractory Castables with Ribbed Stainless-Steel Bars.

Refractory materials containing calcium aluminate cement (CAC) are commonly used in the metallurgical and petrochemical industries due to their exceptional mechanical resistance, even at temperatures exceeding 1000 °C, and do not require additional reinforcement. This study seeks to advance this practice by developing ultra-high-performance structures that offer building protection against fire and explosions. Such structures require bar reinforcement to withstand accidental tension stresses, and the bond performance becomes crucial. However, the compressive strength of these materials may not correlate with their bond resistance under high-temperature conditions. This study investigates the bond behavior of ribbed stainless austenitic steel bars in refractory materials typical for structural projects. The analysis considers three chamotte-based compositions, i.e., a conventional castable (CC) with 25 wt% CAC, a medium-cement castable (MCC) with 12 wt% CAC, a low-cement castable (LCC), and a low-cement bauxite-based castable (LCB); the LCC and LCB castables contain 7 wt% CAC. The first three refractory compositions were designed to achieve a cold compressive strength (CCS) of 100 MPa, while the LCB mix proportions were set to reach a CCS of 150 MPa. Mechanical and pull-out tests were conducted after treatment at 400 °C, 600 °C, 800 °C, and 1000 °C; reference specimens were not subjected to additional temperature treatment. This study used X-ray fluorescence (XRF), X-ray diffraction (XRD), and scanning electron microscopy (SEM) methods to capture the material alterations. The test results indicated that the bonding resistance, expressed in terms of the pull-out deformation energy, did not directly correlate with the compressive strength, supporting the research hypothesis.

A Study on the Microstructure and Mechanical Properties of Portland Cement Incorporating Aluminosilicate Waste.

The influence of aluminosilicate pozzolanic waste, specifically spent fluid catalytic cracking waste (FCCW) and metakaolin waste (MK) from the expanded glass industry, on the properties of hardened Portland cement paste were analysed. The study involved replacing part of cement with FCCW and MK and observing their impact on the hydration, microstructure, density, and compressive strength of hardened cement paste. Various analysis methods were employed, including X-ray diffraction (XRD), thermogravimetric analysis (TG), and scanning electron microscopy (SEM), to understand the changes in the structure of the hardened cement paste during hydration. The findings revealed that FCCW tends to accelerate the cement hydration process due to its high surface area and pozzolanic activity. Notably, the formation of portlandite crystals was observed on FCCW particle surfaces in a specific direction. These crystals appeared smaller and developed in different directions in compositions containing a composite binder with mixture of FCCW and MK in a ratio 1:1. This could be influenced by pozzolanic reactions activated by fine particles of MK and the formation of calcium silicate hydrates (C-S-H) and calcium alumino silicate hydrates (C-A-S-H) in the presence of portlandite. The XRD and TG results indicated that the specimens containing a composite binder exhibited the least amount of portlandite. The compressive strength of these specimens increased compared to the control specimens, although the amount of cement was 9% lower.

The Influence of Acid Casein on the Selected Properties of Lime-Metakaolin Mortars.

One of the ways to modify selected parameters of lime mortars is the use of biopolymers of animal origin, such as bone glue, skin glue, bovine blood, eggs, and casein. These are protein-based biopolymers. Casein is an example of an organic polymer produced from cow's milk. The aim of the work was to investigate the possibilities of improving selected properties of mortars based on hydrated lime and metakaolin. The mixture was modified with powdered technical casein in amounts of 0.5%, 1.5%, 1%, 1.5%, and 2% as a partial mass replacement for the binding mixture. Additionally, the influence of increasing the amount of water on the properties of the mortar with a casein admixture of 2% was checked. This study examined consistency, shrinkage, water absorption, capillary action, porosity, flexural, compressive strength, and Young's modulus. The admixture of casein influenced the properties of the mortar, but not in all cases, and it was possible to determine a clear trend related to the variable amount of casein. Strength properties deteriorated as the amount of casein increased. When air bubbles were introduced into the mortar after the casein was dissolved, the porosity increased as the amount of admixture increased. The moisture properties improved; namely, casein led to a reduction in water absorption and water absorption caused by capillary action. No relationship was observed between the amount of casein and the drying shrinkage. Increasing the amount of water in the mixture led to the expected effects, i.e., an increase in porosity, shrinkage, and water absorption, and a decrease in mechanical strength.

The Impact of Microorganisms on the Performance of Linseed Oil and Tung Tree Oil Impregnated Composites Made of Hemp Shives and Corn Starch.

In this study, the performance characteristics of hemp shives impregnated with linseed oil and tung tree oil (HS)- and corn starch (CS)-based biocomposites containing flame retardants were evaluated before and after treatment with the mixture of bacterium Pseudomonas putida and fungus Rhizopus oryzae. Enzymatic activities and physical-mechanical properties such as water absorption, thickness swelling, compressive strength, and thermal conductivity were tested to evaluate the suitability of selected composites for thermal insulation purposes. In addition, electron microscopy was used to investigate the impact of microorganisms on the microstructure of the material. It was determined that the type of oil used for impregnation significantly affects the properties of biocomposites after 6 months of incubation with mixture of bacterium P. putida and fungus Rh. oryzae. Biocomposites impregnated with linseed oil and after treatment with a mixture of microorganisms had cellulase activity of 25 U/mL, endo ß-1-4-glucanase activity of 26 U/mL, lipase activity of 101 U/mL, only a 10% decrease in compressive strength, 50% higher short-term water absorption, unchanged swelling in thickness, and slightly decreased thermal conductivity compared to control biocomposites. At the same time, biocomposites with tung tree oil had a much more pronounced deterioration of the properties tested, cellulase activity of 28 U/mL, endo ß-1-4-glucanase activity of 37 U/mL, lipase activity of 91 U/mL, two times lower compressive strength and two times higher short-term water absorption, 2.5 times greater thickness swelling, and a slightly increased thermal conductivity. We conclude that linseed oil provides better protection against the action of microorganisms compared to impregnation with tung tree oil.

The Construction of a Footbridge Prototype with Biological Self-Healing Concrete: A Field Study in a Humid Continental Climate Region.

Biological self-healing concrete (BSHC) offers a sustainable and economical way of increasing the lifespan of structures vulnerable to cracking. In recent decades, an enormous research effort has been dedicated to developing and optimizing the bacterial healing process. Nevertheless, most studies have been carried out under laboratory conditions. To verify the effectiveness and longevity of the embedded healing systems under normal service conditions, field studies on BSHC structures must be performed. In the present study, BSHC beams were designed as a structural part of a prototype footbridge. To select the optimal BSHC mix composition, a series of laboratory tests were also carried out. Laboratory tests have shown that the healing ratio in BSHC elements under rain-simulating healing conditions was several times higher in comparison to control specimens. Based on the laboratory results, the BSHC mix composition was selected and applied for structural bridge beams. To the best of the authors' knowledge, the present study reports the first application of BSHC in a prototype footbridge. The long-term data gathered on the healing process in a humid continental climate zone will allow the benefits of biological self-healing to be quantitatively evaluated and will pave the way for the further optimization of this material.

Impact of Cellulolytic Fungi on Biodegradation of Hemp Shives and Corn Starch-Based Composites with Different Flame-Retardants.

Biocomposite boards (BcBs) composed of hemp shives and corn starch are known as thermal insulating or structural building materials. Therefore, they must be stable during exploitation. However, BcBs are exposed to microorganisms present in the environment, and it is of great interest to investigate the biodegradation behaviour of these materials. This work identified microorganisms growing on BcBs that contain either Flovan CGN or expandable graphite as flame retardants and selected fungi such as Rhizopus oryzae and Aspergillus fumigatus to test the way they affect the materials of interest. For this purpose, the enzymatic activity of cellulases and amylases produced by these organisms were determined. In addition, the apparent density as well as compressive strength of the affected boards were evaluated. The results showed that apparent density and compressive strength deteriorated in BcB composition with the Flovan CGN flame retardant. At the same time, the level of deterioration was lower when the expandable graphite was used, suggesting that it also acts as an antimicrobial agent. A scanning electronic microscopy analysis was employed to monitor the growth of microorganisms in the BcBs. Such analysis demonstrated that, regardless of BcB composition, fungi easily penetrate into the middle layers of the material.

Investigations of the Influence of Nano-Admixtures on Early Hydration and Selected Properties of Calcium Aluminate Cement Paste.

In this work, the hydration of calcium aluminate cement (CAC, Al2O3 ≥ 70%) paste with nano admixtures (0, 0.05%, 0.1% and 0.2%) of nano-silica (NS) and carbon nano-cones (NC) when W/CAC = 0.35 was investigated. The methods of calorimetry, thermal analysis, X-ray diffraction (XRD), IR spectroscopy, and scanning electron microscopy (SEM) were used. In addition, the physical and mechanical properties of hardened cement pastes were determined after 3 days of hardening. NS was found to shorten the induction period of CAC hydration and accelerate the time of the secondary heat release effect, especially in the specimens with the highest NS content. The incorporation of NC (up to 0.2%) slows down the hydration process. After 3 days of hydration, the formation of hydration products, such as C2AH8, CAH10, C3AH6 and AH3 hydrates, was observed in CAC pastes, however, the quantitative compositions were different depending on the kind of nano admixture and its amount. SEM results obtained show differences in the effect of NS and NC on the formation of the structure of cement paste during its hardening. Significant changes in CAC paste microstructure were caused by the addition of NS and NC admixtures. Compressive strength was found to increase with the increase of NS and the optimal NS content was found to be 0.10 wt.%. The modification of the cement paste with an NS admixture results in a higher amount of hydrates, lower total porosity, and a higher amount of the smallest pores in the microstructure of the sample. NS and NC influence the hydration behaviour of CAC in different ways, which causes characteristic changes in the microstructure and properties of hardened samples.

The Effect of Active Additives and Coarse Aggregate Granulometric Composition on the Properties and Durability of Pervious Concrete.

Pervious concrete (PCO) has many advantages and applications, such as water pooling reduction, noise attenuation, replenishment of groundwater reserves, etc. However, the use of pervious concrete is limited due to its low compressive strength and durability, especially as a result of portlandite leaching from concrete exposed to flowing water. The effects of active additives (nano SiO2 (NS) spent catalyst generated at the fluid catalytic cracking unit (FCCCw) and paper sludge waste burned at 700 °C (PSw)) along with particle size distribution of the coarse aggregate on the properties and durability of pervious concrete were determined in the research. Active additives used in the binder were found to reduce portlandite leaching from concrete exposed to flowing water to significantly increase the resistance of concrete to freezing and thawing cycles and to increase sound absorption, compressive strength and infiltration rate. In addition, industrial waste (FCCCw and PSw) used as active additives significantly reduced the use of clinker in concrete applied in the construction of water pervious systems. The coarse aggregate size distribution had the greatest effect on the density, ultrasound pulse velocity (UPV), porosity, compressive strength and infiltration rate of pervious concrete.

Numerical Simulation of Thermal Conductivity and Thermal Stress in Lightweight Refractory Concrete with Cenospheres.

The main objective of this paper was to investigate the heat transfer of modified lightweight refractory concrete at the microscopic scale. In this work, such material was treated as a porous composite based on the compound of calcium aluminate cement and aluminosilicate cenospheres. The presence of air inclusions within the cenospheres was an essential factor in the reduction in thermal performance. Due to the intricacy of the subject investigated, our research employed numerical, theoretical, and experimental approaches. Scanning electron microscopy (SEM) imaging was performed to study the composite microstructure with a special focus on geometry, dimensions, and the distribution of cenospheres. Based on the experimental analysis, simplified geometrical models were generated to reproduce the main features of the composite matrix and cenospheres. A finite element framework was used to determine the effective thermal conductivity of such domains as well as the thermal stresses generated in the sample during the heat flow. A considerable difference in thermal properties was revealed by comparing the simulation results of the pure composite matrix and the samples, indicating a varying arrangement of cenosphere particles. The numerical results were complemented by a theoretical study that applied analytical models derived from the two-phase mixture theory-parallel and Landauer. A satisfactory agreement between numerical and theoretical results was achieved; however, the extension of both presented approaches is required.

Evaluation of the Performance of Bio-Based Rigid Polyurethane Foam with High Amounts of Sunflower Press Cake Particles.

In the current study, rigid polyurethane foam (PUR) was modified with 10-30 wt.% sunflower press cake (SFP) filler, and its effect on performance characteristics-i.e., rheology, characteristic foaming times, apparent density, thermal conductivity, compressive strength parallel and perpendicular to the foaming directions, tensile strength, and short-term water absorption by partial immersion-was evaluated. Microstructural and statistical analyses were implemented as well. During the study, it was determined that 10-20 wt.% SFP filler showed the greatest positive impact. For instance, the thermal conductivity value improved by 9% and 17%, respectively, while mechanical performance, i.e., compressive strength, increased by 11% and 28% in the perpendicular direction and by 43% and 67% in the parallel direction. Moreover, tensile strength showed 49% and 61% increments, respectively, at 10 wt.% and 20 wt.% SFP filler. Most importantly, SFP filler-modified PUR foams were characterised by two times lower water absorption values and improved microstructures with a reduced average cell size and increased content in closed cells.

Modification of the Structure and Properties of Lightweight Cement Composite with PVA Fibers.

This study addresses the application of polyvinyl alcohol (PVA) fibers to improve the performance of lightweight cement composites with pozzolans. Blended cement mixes based on expanded glass granules were modified with PVA fibers (Type A: Ø40 µm, L = 8 mm and Type B: Ø200 µm, L = 12 mm). The following research methods were used to analyse the effect of the fibers on the structure of cement matrix and physical-mechanical properties of lightweight composite: SEM, XRD, DTG, calorimetry tests, and standard test methods of physical and mechanical properties. Results from the tests showed that a denser layer of hydrates was formed around the PVA fiber and the amounts of portlandite, CSH, and CASH formed in the specimens with PVA were found to be higher. PVA fibers of Type A accelerated hydration of the cement paste, slightly increased the compressive strength of the lightweight composite, but had no significant effect on the values of density, ultrasonic pulse velocity and flexural strength. The shrinkage of cement composite was significantly reduced using both types of PVA fiber and both types of PVA fibers increased the fracture energy of lightweight cement composite with expanded granules.

Vacuum-Based Impregnation of Liquid Glass into Sunflower Press Cake Particles and Their Use in Bio-Based Rigid Polyurethane Foam.

The study analyses rigid polyurethane (PUR) foam modified with 10-30 wt.% sunflower press cake (SFP) and liquid glass-impregnated sunflower press cake (LG-SFP) particles and their impact on performance characteristics of PUR foams-foaming behaviour, rheology, thermal conductivity, compressive strength parallel and perpendicular to the foaming directions, tensile strength, dimensional stability, short-term water absorption by partial immersion, and thermal stability. Even though the dynamic viscosity and apparent density were increased for SFP and LG-SFP formulations, thermal conductivity values improved by 17% and 10%, respectively, when 30 wt.% of particles were incorporated. The addition of SFP and LG-SFP particles resulted in the formation of more structurally and dimensionally stable PUR foams with a smaller average cell size and a greater content of closed cells. At 30 wt.% of SFP and LG-SFP particles, compressive strength increased by 114% and 46% in the perpendicular direction, respectively, and by 71% and 67% in the parallel direction, respectively, while tensile strength showed an 89% and 85% higher performance at 30 wt.% SFP and LG-SFP particles loading. Furthermore, short-term water absorption for all SFP and LG-SFP modified PUR foam formulations was almost two times lower compared to the control foam. SFP particles reduced the thermal stability of modified PUR foams, but LG-SFP particles shifted the thermal decomposition temperatures towards higher ones.

Prolonging Bacterial Viability in Biological Concrete: Coated Expanded Clay Particles.

One of the biggest challenges in the development of a biological self-healing concrete is to ensure the long-term viability of bacteria that are embedded in the concrete. In the present study, a coated expanded clay (EC) is investigated for its potential use as a bacterial carrier in biological concrete. Eight different materials for coatings were selected considering cost, workability and accessibility in the construction industry. Long-term (56 days) viability analysis was conducted with a final evaluation of each coating performance. Our results indicate that healing efficiency in biological concrete specimens is strongly related to viable bacteria present in the healing agent. More viable bacteria-containing specimens exhibited a higher crack closure ratio. Our data suggest that the additional coating of EC particles improves long-term bacterial viability and, consequently, provides efficient crack healing in biological concrete.

The Effect of Different Plant Oil Impregnation and Hardening Temperatures on Physical-Mechanical Properties of Modified Biocomposite Boards Made of Hemp Shives and Corn Starch.

In this study, tung tree and linseed drying oils, as well as semi-drying hempseed oil, were analyzed as the protective coatings for biocomposite boards (BcB) made of hemp shives, corn starch binder, and the performance-enhancing additives. The hydrophobization coatings were formed at 40, 90, and 120 °C temperatures, respectively. The physical-mechanical properties such as the compressive strength, thermal conductivity, dimensional stability, water absorption, and swelling were tested. In addition, scanning electron microscopy (SEM) was employed for the analysis of the board microstructure to visualize the oil fills and impregnation in pores and voids. It was demonstrated that the compressive strength of oil-modified BcBs compared to uncoated BcBs (at 10% of relative deformation) increased by up to 4.5-fold and could reach up to 14 MPa, water absorption decreased up to 4-fold (from 1.34 to 0.37 kg/m2), swelling decreased up to 48% (from 8.20% to 4.26%), whereas the thermal conductivity remained unchanged with the thermal conductivity coefficient of around 0.085 W/m·K. Significant performance-enhancing properties were obtained due to the formation of a protective oil film when the tung tree oil was used.

Analysis of Physical and Mechanical Properties of the Mortar in the Historic Retaining Wall of the Gediminas Castle Hill (Vilnius, Lithuania).

This study analysed the results of the joint research into the building materials of the historic masonry of the retaining wall of the Gediminas Castle Hill dating back to the end of the 13th and beginning of the 14th centuries. Core samples for material testing were collected along the entire height of the retaining wall to assess its load bearing capacity. Boreholes were drilled 600⁻1000 mm from the exterior of the wall to determine the properties of the ceramic bricks and lime mortar that were not affected by external factors. The analysis of the microstructure and chemical composition, mechanical and physical properties of the ceramic bricks and lime mortar is presented. The high compressive strength (8.5 MPa) of the lime mortar was the result of using hydraulic lime and crumbs of ceramic bricks as mortar aggregate.