Open access
Technical Papers
Dec 20, 2018

Lightweight Alkali-Activated Material from Mining and Glass Waste by Chemical and Physical Foaming

Publication: Journal of Materials in Civil Engineering
Volume 31, Issue 3

Abstract

A foamed alkali-activated material (FAAM) based on tungsten mining waste (TMW) and municipal waste glass (WG) is fabricated by using aluminum powder and organic surfactant foaming agents. The compressive strength and density of the FAAM are investigated in terms of different parameters of production and formulation, including curing temperature as well as the dosage of Na2O, foaming agent, foam catalyzing agent, and stabilizing agent. FAAM made with aluminum powder consists of smaller open macropores and exhibits higher compressive strength compared with FAAMs with larger closed macropores obtained by organic surfactant counterparts. The final aluminum powder–based FAAM reaches a 7-day compressive strength in excess of 3 MPa and a density below 0.7  g/cm3. The implementation of an appropriate amount of foam stabilizer leads to a further 15% increase in compressive strength, 6% reduction in density, and a thermal conductivity below 0.1  W/mK. The FAAM explored in this study represents an ideal material for building envelope insulation.

Formats available

You can view the full content in the following formats:

Acknowledgments

Partial finance support from the European Commission Horizon 2020 Marie Skłodowska- Curie Research and Innovation Staff Exchange scheme through Grant No. 645696 [i.e., the Reuse of Mining Waste into Innovative Geopolymeric-based Structural Panels, Precast, Ready Mixes and Insitu Applications (REMINE) project] is greatly acknowledged.

References

Abdullah, M. M. A. B., K. Hussin, M. Bnhussain, K. N. Ismail, Z. Yahya, and R. Abdul Razak. 2012. “Fly ash-based geopolymer lightweight concrete using foaming agent.” Int. J. Mol. Sci. 13 (6): 7186–7198. https://doi.org/10.3390/ijms13067186.
Amran, Y. H. M., N. Farzadnia, and A. A. Abang Ali. 2015. “Properties and applications of foamed concrete: A review.” Constr. Build. Mater. 101: 990–1005. https://doi.org/10.1016/j.conbuildmat.2015.10.112.
Arellano Aguilar, R., O. Burciaga Díaz, and J. I. Escalante García. 2010. “Lightweight concretes of activated metakaolin-fly ash binders, with blast furnace slag aggregates.” Constr. Build. Mater. 24 (7): 1166–1175. https://doi.org/10.1016/j.conbuildmat.2009.12.024.
Baetens, R., B. P. Jelle, and A. Gustavsen. 2011. “Aerogel insulation for building applications: A state-of-the-art review.” Energy Build. 43 (4): 761–769. https://doi.org/10.1016/j.enbuild.2010.12.012.
Baetens, R., B. P. Jelle, J. V. Thue, M. J. Tenpierik, S. Grynning, S. Uvsløkk, and A. Gustavsen. 2010. “Vacuum insulation panels for building applications: A review and beyond.” Energy Build. 42 (2): 147–172. https://doi.org/10.1016/j.enbuild.2009.09.005.
Bai, C., G. Franchin, H. Elsayed, A. Zaggia, L. Conte, H. Li, and P. Colombo. 2017. “High-porosity geopolymer foams with tailored porosity for thermal insulation and wastewater treatment.” J. Mater. Res. 32 (17): 3251–3259. https://doi.org/10.1557/jmr.2017.127.
CEN (European Committee for Standardization). 2016. Methods of testing cement. Part 1: Determination of strength. EN 196-1:2016. Brussels, Belgium: CEN.
Cheng-Yong, H., L. Yun-Ming, M. M. A. B. Abdullah, and K. Hussin. 2017. “Thermal resistance variations of fly ash geopolymers: Foaming responses.” Sci. Rep. 7 (1): 45355. https://doi.org/10.1038/srep45355.
Dhir, R. K., M. D. Newlands, and A. McCarthy. 2005. Use of foamed concrete in construction. London: Thomas Telford.
Duan, P., C. Yan, W. Zhou, and W. Luo. 2016. “Fresh properties, mechanical strength and microstructure of fly ash geopolymer paste reinforced with sawdust.” Constr. Build. Mater. 111: 600–610. https://doi.org/10.1016/j.conbuildmat.2016.02.091.
Duxson, P., A. Fernández -Jiménez, J. L. Provis, G. C. Lukey, A. Palomo, and J. S. J. van Deventer. 2007. “Geopolymer technology: The current state of the art.” J. Mater. Sci. 42 (9): 2917–2933. https://doi.org/10.1007/s10853-006-0637-z.
Feng, J., R. Zhang, L. Gong, Y. Li, W. Cao, and X. Cheng. 2015. “Development of porous fly ash-based geopolymer with low thermal conductivity.” Mater. Des. 65: 529–533. https://doi.org/10.1016/j.matdes.2014.09.024.
Görhan, G., and G. Kürklü. 2014. “The Influence of the NaOH solution on the properties of the fly ash-based geopolymer mortar cured at different temperatures.” Compos. Part B Eng. 58: 371–377. https://doi.org/10.1016/j.compositesb.2013.10.082.
Hajimohammadi, A., T. Ngo, and P. Mendis. 2017. “How does aluminium foaming agent impact the geopolymer formation mechanism?” Cem. Concr. Compos. 80: 277–286. https://doi.org/10.1016/j.cemconcomp.2017.03.022.
Hlaváček, P., V. Šmilauer, F. Škvára, L. Kopecký, and R. Šulc. 2015. “Inorganic foams made from alkali-activated fly ash: Mechanical, chemical and physical properties.” J. Eur. Ceram. Soc. 35 (2): 703–709. https://doi.org/10.1016/j.jeurceramsoc.2014.08.024.
Kastiukas, G., X. Zhou, and J. Castro-Gomes. 2016. “Development and optimisation of phase change material-impregnated lightweight aggregates for geopolymer composites made from aluminosilicate rich mud and milled glass powder.” Constr. Build. Mater. 110: 201–210. https://doi.org/10.1016/j.conbuildmat.2016.02.029.
Kastiukas, G., X. Zhou, and J. Castro-Gomes. 2017. “Preparation conditions for the synthesis of alkali-activated binders using tungsten mining waste.” J. Mater. Civ. Eng. 29 (10): 04017181. https://doi.org/10.1061/(ASCE)MT.1943-5533.0002029.
Liu, M. Y. J., U. J. Alengaram, M. Z. Jumaat, and K. H. Mo. 2014. “Evaluation of thermal conductivity, mechanical and transport properties of lightweight aggregate foamed geopolymer concrete.” Energy Build. 72: 238–245. https://doi.org/10.1016/j.enbuild.2013.12.029.
Mousa, M. A., and N. Uddin. 2009. “Experimental and analytical study of carbon fiber-reinforced polymer (FRP)/autoclaved aerated concrete (AAC) sandwich panels.” Eng. Struct. 31 (10): 2337–2344. https://doi.org/10.1016/j.engstruct.2009.05.009.
Najif, I., and H. El-Hassan. 2018. “Development and characterization of fly ash-slag blended geopolymer mortar and lightweight concrete.” J. Mater. Civ. Eng. 30 (4): 04018029. https://doi.org/10.1061/(ASCE)MT.1943-5533.0002209.
Novais, R. M., L. H. Buruberri, G. Ascensão, M. P. Seabra, and J. A. Labrincha. 2016. “Porous biomass fly ash-based geopolymers with tailored thermal conductivity.” J. Clean. Prod. 119: 99–107. https://doi.org/10.1016/j.jclepro.2016.01.083.
O’Grady, M., A. A. Lechowska, and A. M. Harte. 2017. “Quantification of heat losses through building envelope thermal bridges influenced by wind velocity using the outdoor infrared thermography technique.” Appl. Energy 208: 1038–1052. https://doi.org/10.1016/j.apenergy.2017.09.047.
Pargana, N., M. D. Pinheiro, J. D. Silvestre, and J. de Brito. 2014. “Comparative environmental life cycle assessment of thermal insulation materials of buildings.” Energy Build. 82: 466–481. https://doi.org/10.1016/j.enbuild.2014.05.057.
Ravikumar, D., and N. Neithalath. 2012. “Effects of activator characteristics on the reaction product formation in slag binders activated using alkali silicate powder and NaOH.” Cem. Concr. Compos. 34 (7): 809–818. https://doi.org/10.1016/j.cemconcomp.2012.03.006.
Rovnaník, P. 2010. “Effect of curing temperature on the development of hard structure of metakaolin-based geopolymer.” Constr. Build. Mater. 24 (7): 1176–1183. https://doi.org/10.1016/j.conbuildmat.2009.12.023.
Shen, L., J. I. Haufe, and M. Patel. 2009. “Product overview and market projection of emerging bio-based plastics.” Accessed February 12, 2018. https://bit.ly/2L9wVyz.
Sindhunata van Deventer, J. S. J., G. C. Lukey, and H. Xu. 2006. “Effect of curing temperature and silicate concentration on fly-ash-based geopolymerization.” Ind. Eng. Chem. Res. 45 (10): 3559–3568. https://doi.org/10.1021/ie051251p.
Stubenrauch, C., and R. von Klitzing. 2003. “Disjoining pressure in thin liquid foam and emulsion films-new concepts and perspectives.” J. Phys. Condens. Matter 15 (27): R1197. https://doi.org/10.1088/0953-8984/15/27/201.
Tenn, N., F. Allou, C. Petit, J. Absi, and S. Rossignol. 2015. “Formulation of new materials based on geopolymer binders and different road aggregates.” Ceram. Int. 41 (4): 5812–5820. https://doi.org/10.1016/j.ceramint.2015.01.010.
Thanoon, W. A., M. S. Jaafar, M. R. Abdul Kadir, A. A. Abang Ali, D. N. Trikha, and A. M. S. Najm. 2004. “Development of an innovative interlocking load bearing hollow block system in Malaysia.” Constr. Build. Mater. 18 (6): 445–454. https://doi.org/10.1016/j.conbuildmat.2004.03.013.
Unwin, J., M. R. Coldwell, C. Keen, and J. J. McAlinden. 2013. “Airborne emissions of carcinogens and respiratory sensitizers during thermal processing of plastics.” Ann. Occup. Hyg. 57 (3): 399–406. https://doi.org/10.1093/annhyg/mes078.
Wang, M. R., D. C. Jia, P. G. He, and Y. Zhou. 2010. “Influence of calcination temperature of kaolin on the structure and properties of final geopolymer.” Mater. Lett. 64 (22): 2551–2554. https://doi.org/10.1016/j.matlet.2010.08.007.
Wei, S., C. Yiqiang, Z. Yunsheng, and M. R. Jones. 2013. “Characterization and simulation of microstructure and thermal properties of foamed concrete.” Constr. Build. Mater. 47: 1278–1291. https://doi.org/10.1016/j.conbuildmat.2013.06.027.
Zhang, Z., J. L. Provis, A. Reid, and H. Wang. 2015. “Mechanical, thermal insulation, thermal resistance and acoustic absorption properties of geopolymer foam concrete.” Cem. Concr. Compos. 62: 97–105. https://doi.org/10.1016/j.cemconcomp.2015.03.013.

Information & Authors

Information

Published In

Go to Journal of Materials in Civil Engineering
Journal of Materials in Civil Engineering
Volume 31Issue 3March 2019

History

Received: Mar 23, 2018
Accepted: Aug 14, 2018
Published online: Dec 20, 2018
Published in print: Mar 1, 2019
Discussion open until: May 20, 2019

Authors

Affiliations

Gediminas Kastiukas, Ph.D.
Research Fellow, Dept. of Civil and Environmental Engineering, Brunel Univ. London, Uxbridge, Middlesex UB8 3PH, United Kingdom.
Xiangming Zhou, Ph.D., M.ASCE [email protected]
Professor, Dept. of Civil and Environmental Engineering, Brunel Univ. London, Uxbridge, Middlesex UB8 3PH, United Kingdom (corresponding author). Email: [email protected]
Kai Tai Wan, Ph.D.
Lecturer, Dept. of Civil and Environmental Engineering, Brunel Univ. London, Uxbridge, Middlesex UB8 3PH, United Kingdom.
João Castro Gomes, Ph.D.
Professor, Centre of Materials and Building Technologies, Univ. of Beira Interior, Covilhã 6200, Portugal.

Metrics & Citations

Metrics

Citations

Download citation

If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.

Cited by

View Options

Media

Figures

Other

Tables

Share

Share

Copy the content Link

Share with email

Email a colleague

Share