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Nowadays there are several applications of mineral recycling materials and residues. At present an assessment method for the use of secondary raw materials, which considers sustainability aspects, does not exist. In the framework of the German DAfStb/BMBF research project 'Sustainable Building with Concrete' an assessment concept was developed. It includes the following four assessment steps: I. Basic considerations, II. Advantages for sustainable construction, III. Alternative paths for application, and IV. Sensitivity analysis. The concept was developed on the basis of recycled concrete aggregates, which are already used according to German standards. Afterwards, it was applied and verified by the evaluation of the utilisation of municipal solid waste incinerator bottom ashes.
Mineral building materials are generally heterogeneous and porous solids. Their engineering properties are closely associated with their porosity and pore-size distribution, which can be studied by mercury intrusion. The entire pore-size distribution curves are used to determine changes in the pore structure of a material class in a qualitative way. Certain parameters derived from pore-size distributions can be correlated to engineering properties. These key values are applied as criteria to evaluate the quality and durability of a building material. However, because of the heterogeneity of natural and artificial building materials and the influence of moisture content on their pore structure the results are strongly affected by preparation conditions such as sampling and drying. A correct analysis requires a knowledge of these effects. The paper describes the use of mercury porosimetry to study mineral building materials such as cementitious materials, bricks, and renderings. Furthermore, the influence of preparation effects on the precision of measurements is discussed.
Lightweight aggregates (LWA) are mixtures of porous grains of mineral origin characterised by particle bulk densities less than 2000 kg/m³ or loose bulk densities less than 1200 g/m³. They are used in concrete, mortar and grout in buildings, roads and civil engineering works. LWA are commonly produced by thermal treatment of natural raw materials such as clay, shale and other clayey or igneous rocks at temperatures between 1000 °C and 1300 °C. Expanded clay, expanded shale, vermiculite and expanded perlite are well-known aggregates used in the construction industry today. But porous LWA can also be manufactured from mineral residues, such as waste glass or masonry rubble, by thermal expending process. The source materials must satisfy two conditions. First, their chemical composition must be in balance between fluxing agents, silica and alumina to reach pyroplastic conditions at an economically viable temperature to develop sintering and melting phases of proper viscosity. Second, the material should contain some components, which ensure gas release during the partial melting, to form expanded porous particles. Lightweight aggregates usually show a heterogeneous and macroporous pore structure. Their solid skeleton is continually opened by large bulky pores whereas the skeletal walls contain many small pores. Additionally, the grains consist of partly melted areas. The specific microstructural and morphological characteristics of different LWA are strongly influenced by the great variety of source materials and the particular manufacturing conditions.
Recycling granules (RC granules), which are lightweight aggregates made from masonry rubble containing about 50 % brick material, are already described in terms of manufacturing process, engineering properties and microstructure in. The objective of this study is to compare the chemical, physical, mineralogical and microstructural characteristics of RC granules with those of commercially produced expanded clay aggregates. Results of the ICP optical emission spectrometry, X-ray diffraction, thermal analysis, fusibility tests, particle shape analysis, porosity measurements, mercury intrusion porosimetry und environmental scanning electron microscopy are presented. The microstructural characteristics are correlated with engineering properties of the lightweight aggregates, such as water absorption and particle strength.
The study was part of two research projects that were supported by the Federal Ministry of Education and Research in the framework of the funding initiative “r2-Innovative Technologies for Resource Efficiency - Resource-Intensive Production Processes” and the Bundesministerium für Wirtschaft und Energie in the framework of the Central Innovation Programme for SMEs.
This paper investigates fast and inexpensive measurement methods for defect detection in parts produced by Additive Manufacturing (AM) with special focus on lattice parts made of ceramics. By Lithography-based Ceramic Manufacturing, parts were built both without defects and with typical defects intentionally introduced. These defects were investigated and confirmed by industrial X-ray Computed Tomography. Alternative inexpensive methods were applied afterwards on the parts such as weighing, volume determination by Archimedes method and gas permeability measurement. The results showed, that defects resulting in around 20% of change in volume and mass could be separated from parts free of defects by determination of mass or volume. Minor defects were not detectable as they were in the range of process-related fluctuations. Permeability measurement did not allow to safely identify parts with defects. The measurement methods investigated can be easily integrated in AM process chains to support quality control.
Alkaline reactions of paper sludge combustion ash at low temperature (60 °C) were performed using a calcite-rich paper ash (PA 1) and a gehlenite-rich ash (PA 2). Strong alkaline conditions (8, 12, 16 M NaOH) were revealed at reaction times of 1–4 h and 12–24 h. Reactions were performed with pure ashes and in the presence of NaAlO2. The products were characterized by XRD, FTIR, SEM/EDX, gravimetry and chemical analysis. The conversion was found to proceed mainly in the period between 1 and 4 h. Portlandite and hydrogarnet were observed from PA 1 in 8 M NaOH. Onset of formation of Ca4Al2O6CO·311H2O beside Ca(OH)2 could be analyzed after reaction of PA 1 in 12 M and 16 M NaOH. Addition of NaAlO2 favored crystallization of hydrogarnet and Ca4-Al2O6CO·311H2O. For PA 2 gehlenite remained stable, but a high portlandite fraction was observed. Addition of NaAlO2 yielded hydrogarnet beside gehlenite in 8 M NaOH. Higher alkalinities favored crystallization of Ca4Al2O6-CO·311H2O and onset of dissolution of gehlenite. Finally transformation of Ca4Al2O6CO·311H2O into sodium aluminum silicate hydrate was observed. All results were discussed with regard to heavy metal distribution of the initial PA between the alkaline digestion solution and the products. In conclusion suitable applications of the products were proposed.
Earth buildings and adobe construction have been in use for thousands of years. Loam is locally available, environmentally friendly and has a small CO2 footprint mainly resulting from extraction and transport. Because of these reasons loam is one of the building materials of the future.
Water resistance is an important aspect when using loam as a construction material. If the structural option of building protruding roofs cannot be implemented, the water resistance of clay can be improved by stabilization.
Positive properties of the material should not be diminished by stabilization. For example, the desired regulation of air humidity, which however cannot be fully preserved by cement stabilization.
For an alternative and more appropriate stabilisation, different mixtures with calcined clays with alkali activator were examined. The calcination temperature for clays is usually lower than for cement and starts at 600° C. The calcined clays therefore also have a lower CO2 footprint compared to cement. To keep the mixture environmentally friendly potassium was used as alkali ion. It could be proven that the alkali activated polymer enhances water resistance of the loam mixture. Provided some further optimization the material shows potential to replace cement without compromising on the positive properties of clay.
This paper is a case study of complete substitution of sodium-metasilicate in zeolite Na-A synthesis by an electrostatic filterash (FA) arising in high amounts during silane waste incineration process.The silicate abundant FA is a suitable material for reinsertion in zeolite chemistry. This is shown in the presented investigation by the development of a model reaction process at low temperatures (50–60 °C) and short times (1.5–4 h). The experiments were performed under addition of NaAlO2 and variation of the alkalinity and the reaction period. Characterization and fine tuning of the process was mainly done by studying the kinetics of FA digestion and zeolite crystallization by XRD and chemical analyses (ICP-OES) of solutions and solids. It could be shown that pure FA was mostly dissolved (98%) in 8 m NaOH already after 1 h. Addition of NaAlO2 and crystallization for further 60 min under optimized conditions at 50 °C yielded to a suitable product. It consists of zeolite Na-A (92% by mass) beside some hydrosodalite (8% by mass). According to this low temperature short time process this study is a contribution for the development of energy efficient recycling solutions.