Constr. Mater., Volume 2, Issue 4 (December 2022) – 7 articles

Building Information Modeling (BIM) is increasingly establishing a model-based work process in the construction industry. Though it can be considered the standard for the planning of new buildings, the use cases for existing buildings are still limited. Nonetheless, BIM models provide promising possibilities which are increasingly being researched in different fields of application. At the Institute for Building Materials Research (ibac) at RWTH Aachen University, a novel approach for maintenance and repair of reinforced concrete is being developed, using BIM models enriched with machine-readable diagnosis data. This paper proposes a digital workflow and highlights the added value for planning repair measures. Using BIM in maintenance and repair can accelerate the planning process and decrease the required material consumption for the execution. Full article

To develop a more reactive pozzolan for supplementary cementitious materials (SCMs), the co-calcination of kaolinite and limestone was investigated for its contribution to hydration of blended cement. Kaolinite (with ~50 wt% quartz impurity) was calcined at 700 °C, and a mixture of kaolinite and limestone was calcined at 800 °C. These activated SCMs were added to ordinary Portland cement (OPC), replacing ca. 30 wt% of the OPC. The compressive strength of these blended cement paste samples was measured after 28 and 90 days, while the hydration products and microstructural development in these blended cement pastes were analyzed by X-ray diffraction (XRD), thermogravimetric analysis (TGA), and scanning electron microscopy (SEM). The results revealed that adding free lime to OPC, together with metakaolin, led to enhanced compressive strength. The compressive strength of this new blended cement paste reached 113% and 112% of the compressed strength of pure OPC paste after 28 and 90 days of hydration, respectively. Furthermore, this study showed that the improvement was due to the increased consumption of Portlandite (CH), the formation of calcium aluminosilicate hydrate (CASH), and the reduction of porosity in the sample containing free lime and metakaolin. Full article

Sustainability in construction is related to the use of industrial by-products, such as fly ash (FA). FA varies in chemical/mineralogical composition, depending on the raw materials burnt during its production. While FA produced from coal-fired power stations is extensively used in cementitious composites, heavy oil FA produced from the firing of heavy fuels (e.g., mazut or diesel) remains largely unused. This paper focuses on the novel use of heavy fuel fly ash (HFFA), as a replacement of Class F FA, in high-volume fly ash self-compacting composites. Two different grain size distributions of HFFA were used in quantities 5–15% w/w of cement and Class F FA for the production of the composites. The assessment of the physico-mechanical properties and microstructure of the end-products at different curing ages suggests that HFFA may be used at quantities ≤10% w/w, without any negative effects. In fact, depending on the quantity and grain size distribution of the HFFA, this may even improve some of the properties of the end-products in the long term, provided that a careful mix design is adopted. The findings show the potential of sustainable reuse of HFFA and are beneficial for its incorporation into design codes. Full article

This study investigates the piezoresistive (self-sensing) properties of short stainless-steel fiber-reinforced mortar under varying temperature conditions. Different reinforced mortars were produced by varying fiber and aggregate content. First, Electrical Impedance Spectroscopy (EIS) measurements were used to characterize the electrical properties of the mortar specimens. EIS measurements were performed at temperatures of 24 °C, 35 °C, and 50 °C. Second, to investigate the self-sensing capacity of the different composites, the fractional changes of electrical impedance at 1 kHz were monitored under two conditions: temperature variation alone (cooling down from 35 °C or 50 °C to room temperature), and temperature variation combined with cyclic compressive loading (up to 5 MPa). The results of the former were used to compensate for the effect of temperature variations in the latter. Both temperature and mechanical loading produced meaningful variations in the electrical impedance and piezoresistivity of the investigated composites. Conclusions are drawn with respect to the stress and temperature sensitivity of the composites. The real and imaginary parts of the electrical impedance of the mortar produced with the highest fiber volume fraction (0.01%) and higher aggregate content (volume fraction of 60%) were distinctly sensitive to temperature and stress, which suggests the possibility of using the same composite as a stress and temperature sensor. Full article

Sawdust and coconut coir dust are agro-wastes/by-products which are suitable for use as raw materials to manufacture unfired clay blocks due to their excellent physical and mechanical properties. A limited number of studies have been conducted on the utilisation of these agro-wastes in clay block production, and they have mostly been devoted to investigating the physicomechanical properties, with less attention given to the thermal properties. Moreover, the majority of the studies have used chemical binders (cement and lime) in combination with agro-waste, thus increasing the carbon footprint and embodied energy of the samples. Furthermore, no research has been performed on the thermal performance of these agro-wastes when incorporated into clay blocks at the wall scale. Therefore, to address these limitations, the present study developed unfired clay blocks incorporating sawdust and coconut coir dust (0, 2.5, 5, and 7.5% by weight), without the use of chemical binders, and evaluated their thermal performance, both at the individual and wall scales. The experiments were divided into two phases. In the first phase, individual sample blocks was tested for basic thermal properties. Based on the results of the first phase, small walls with dimensions of 310 mm × 215 mm × 100 mm were built in the second phase, using the best performing mixture from each waste type, and these were assessed for thermal performance using an adapted hot box method. The thermal performance of the walls was evaluated by measuring the heat transfer rate from hot to cold environments and comparing the results to the reference wall. The results showed that thermal conductivity decreased from 0.36 W/mK for the reference sample, to 0.19 W/mK for the 7.5% coconut coir dust sample, and 0.21 W/mK for the 7.5% sawdust sample, indicating an improvement in thermal insulation. Furthermore, the coconut coir dust and sawdust sample walls showed a thermal resistance improvement of around 48% and 35%, respectively, over the reference sample wall. Consequently, the findings of this study will provide additional essential information that will help in assessing the prospective applications of sawdust and coconut coir dust as the insulating material for manufacturing unfired clay blocks. Full article

One of the promising technologies to produce carbon textile-reinforced concrete structures is extrusion. For defect-free extrusion, high requirements are placed on the fresh concrete, since it must be transportable through the augers in the extruder and must not change the desired geometric shape after leaving the mouthpiece. For the rheologic description of suitable concretes or mortars for the extrusion process, there is currently a lack of test methods to characterise the fresh concrete before extrusion. At present, new mixtures are first tested in elaborate trials on laboratory extruders before they can be transferred to production scale. The development of compounds is strongly dependent on the know-how and experience of the users. Within the scope of this paper, different methods were investigated and systematic suitability tests for a successful extrusion have been carried out. The results show that the fresh mortar can only be roughly described by the measured data during the mixing process, such as the temperature or the torque. The use of a capillary rheometer only allows a basic characterisation of the fresh mortar. A clear differentiation of the fresh mortar can be made with the help of sphere penetration tests. These allow the mortar to be classified as unsuitable for the extrusion process or as extrudable before the extrusion process, and the suitability of new mixtures can be assessed in advance. The newly developed method offers the possibility of greatly accelerating the implementation of new formulations for the extrusion process, regardless of the experience of the subsequent users, and reducing the need for complex experiments using laboratory extruders. Full article

Global cement production has reached 3.9 billion tons. However, the clinkerization process, which is the basis of cement production, is responsible for an approximate annual global CO₂ emission of 2 billion tons. As part of CEMBUREAU’s 5C strategy, the European cement industry aims to achieve carbon neutrality throughout the cement-concrete value chain by 2050. This article is a continuation of the previous article on the indirect mechanosynthesis clinkerization process, which combines mechanical activation (high-energy milling) and thermal treatment at lower temperatures (from 900 °C) than those used for conventional clinkerization to produce clinker. With this process, we manufactured cement and clinker from industrial and laboratory raw mixes, which had to be rectified by adding kaolinite in compliance with the different cement indicators (LSF, SM, AM). The cement and clinker produced by indirect mechanosynthesis (15 min of mechanical activation and heat treatment 900 °C or 1200 °C) were characterized. In order to test the hydraulic properties of the cement produced, cement pastes were made. Mechanical and structural studies were carried out (between 70 and 90% of C₂S). Mechanical tests revealed for 7 curing days, the values of 3.60 and 7.60 MPa at 900 °C and 1200 °C, respectively, in comparison to commercial cements CEM I and CEM III (23.03 and 19.14 MPa). Full article