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Polymer absorption by lightweight concretes to improve bonding between cement and aggregate and to increase strength of cement is discussed. Compressive strength of treated cement is compared with strength of untreated product. Process for producing polymers is described.
An off-spec fly ash-based spherical lightweight aggregate (LWA), designated as Spherical Porous Reactive Aggregate (SPoRA), was manufactured through a lab pilot-scale production and its engineering properties, including specific gravity, dry rodded unit weight, water absorption, mechanical performance, and pore structure, were evaluated. Using SPoRA, lightweight concrete (LWC) samples were made and their fresh, mechanical, and hydration properties were assessed and compared with LWC samples made using two commercial LWA available in the US market. The results indicated that fine and coarse SPoRA had 72 h water absorption capacities of 16.4 % and 20.9 %, respectively, which were higher than that of the two commercial LWAs. Higher saturated surface dry specific gravity of SPoRA compared to commercial LWAs led to a higher fresh density for the corresponding LWC. Using X-ray computed tomography, large spherical type pores were observed in SPoRA similar to those in the commercial slate-based LWA. Additionally, the pore size distribution of SPoRA, characterized by a dynamic vapor sorption analyzer, indicated that more than 97 % of the pores had diameters greater than 50 nm. SPoRA’s average bulk crushing strength was 6.8 MPa which was smaller than commercial LWA and was potentially attributed to the differences in manufacturing processes. Nonetheless, SPoRA LWC with 28 days compressive strength of 29 MPa passed the ASTM C330 requirement and had a comparable strength with LWC prepared with the commercial LWAs indicating lesser importance for the LWA strength. SPoRA LWC had a flowability of 5 % compared to LWC prepared with commercial LWAs having flowability of 18 %. This observation was potentially related to the fluxing agent used in the SPoRA production. SPoRA had a 70 % degree of hydration at 12 days which was comparable with that of LWC prepared with commercial LWA.
A lightweight concrete composition includes the concrete components, per yd3 of concrete: Type III Portland cement (lb/yd3) 200-900; metakaolin (lb/yd3) 100-520; calcium sulfoaluminate cement (CSA) (lb/yd3) 40-840; 3/8″ lightweight expanded slate aggregate (lb/yd3) 70-550; lightweight fine expanded slate aggregate (lb/yd3) 300-550; expanded glass fine aggregate (0.5-1 mm) 35-90 (lb/yd3); expanded glass fine aggregate (1-2 mm) 35-90 (lb/yd3); water (lb/yd3) 300-350; CSA cement set retarder 0.015 to 0.06 oz per lb of CSA cement; high-range water-reducing admixture 120-1000 (fl. oz/yd3); hydration controlling admixture 0-80 (fl. oz/yd3); reinforcing non-metallic lightweight fibers <1.5″ in length 0-8 (lb/yd3); wherein the concrete has a flexural strength of at least 600 psi at 12 hours, a density of 95 to 110 lb/ft3, and a compressive strength at 28 days of at least 7,000 psi. A lightweight concrete wythe and method of making a lightweight concrete wythe are also disclosed.
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Here, this paper studies the pathways to formulate lightweight and ultra-lightweight 3D printable cementitious composites. A hybrid approach was proposed by combining the advantages of traditional chemical-induced foaming (foaming approach) and lightweight particulate inclusions (synthetic foam approach). A comprehensive experimental program was conducted to evaluate the effects of foaming agents and fly ash cenosphere (FAC) on the printability, microstructure, mechanical and thermal properties of 3D printed samples. The results showed that the hybrid approach could produce a mixture with a density as low as 470 kg/m 3 while ensuring good flowability and buildability owing to the lubricating effect of foaming and supporting skeleton formed by FAC. In addition, a three-step homogenization procedure was also developed to predict the effective elastic modulus and thermal conductivity of 3D printable cementitious composites and cementitious foam. The findings of the study highlighted the effectiveness of the hybrid approach in formulating 3D printable ultra-lightweight cementitious composites in thermal insulation and acoustic applications.
Floating offshore wind turbines are a promising technology for addressing energy needs by utilizing wind resources offshore. The current state of the art is based on heavy, expensive platforms to survive the ocean environment. Typical design techniques do not involve optimization because of the computationally expensive time domain solvers used to model motions and loads in the ocean environment. However, this design uses an efficient frequency domain solver with a genetic algorithm to rapidly optimize the design of a novel floating wind turbine concept. The concept utilizes a liquid ballast mass to mitigate motions on a lightweight post-tensioned concrete platform. The simple cruciform-shaped design of the platform made of post-tensioned concrete is less expensive than steel, reducing the raw material and manufacturing cost. The use of ballast water to behave as a tuned mass damper allows a smaller platform to achieve the same motions as a much larger platform, thus reducing the mass and cost. The optimization techniques applied with these design innovations resulted in a design with a levelized cost of energy of USD 0.0753/kWh, roughly half the cost of the current state of the art.
Fibrous insulation and refractory concrete are used for logs as well as fireproof walls, incinerator bricks, planters, and roof shingles. Insulation is lighter and more shock resistant than fireclay. Lightweight slag bonded with refractory concrete serves as aggregrate.
A novel calcium carbonate cement system that mimics the naturally occurring mineralization process of carbon dioxide to biogenic or geologic calcium carbonate deposits was developed utilizing carbon dioxide-containing flue gas and high-calcium industrial solid waste as raw materials. The calcium carbonate cement reaction is based on the polymorphic transformation from metastable vaterite to aragonite and can achieve >40 MPa compressive strength. Due to its unique properties, the calcium carbonate cement is well suited for building materials applications with controlled factory manufacturing processes that can take advantage of its rapid curing at elevated temperatures and lower density for competitive advantages. Examples of suitable applications are lightweight fiber cement board and aerated concrete. The new cement system described is an environmentally sustainable alternative cement that can be carbon negative, meaning more carbon dioxide is captured during its manufacture than is emitted.
The main goal of the project was to create a continuous manufacturing process for carbon foam that operates at atmospheric pressure and can generate well-formed carbon foam panels and lightweight aggregates. This objective was accomplished and has enabled a platform where carbon foam products can be manufactured at significantly reduced cost and cycle time relative to the conventional high-pressure batch process, which in turn can enable the manufacture of much larger volumes of carbon foam. All these features should enable carbon foam to enter much larger markets and create meaningful demand for U.S. coal. Carbon foam panels and aggregate both consisted of at least 70 weight percent carbon per program requirements (typical was over 90-wt%), and at least 51 weight percent of the carbon was to be coal derived (typical was over 90-wt% carbon was from coal). Analyses regarding life cycle, technoeconomics, and final technological gaps have been documented in separate reports. This final report documents the methods used to attain the main goal and describes the technical results.
Highlights: • An ultra high-performance lightweight cementitious composite (UHP-LCC) was designed. • The UHP-LCCs had ultra high strength (>120 MPa) and very low density (3 ). • The UHP-LCCs had high structural efficiency, good functional properties and superior durability. • The strategies and mechanisms on achieving UHP-LCCs with excellent performance were proposed. High strength and light weight are two recent opposite development trends of concrete. This study proposed a design concept of an ultra high-performance lightweight cementitious composite (UHP-LCC), which had a compressive strength of higher than 120 MPa and an air-dried density down to around 1800 kg/m{sup 3}. The UHP-LCCs were innovatively developed by incorporating micro-sized hollow particles with a high strength shell (hollow glass microspheres, HGM) into an ultra-high performance cementitious composite (UHPC). The roles of HGM in the UHP-LCCs were investigated by evaluating the reactivity of the HGM and the mechanisms on achieving the excellent mechanical properties, low density and superior durability were revealed. The Chapelle test results showed that the HGM exhibited some pozzolanic reactivity, which facilitated the reaction between the shell of HGM and the alkali hydration products of the paste matrix. This chemical reaction was conducive to improving the HGM-paste interface and enhancing the mechanical properties. With the use of microspheres with a high stiff shell, the fundamental properties of the UHP-LCCs including thermal insulation, sound absorption, resistance to water ingress and electrical resistivity were improved significantly. The strategies for preparing the UHP-LCCs with high structural efficiency and great performance were proposed. The results of this study provide a new approach for designing and producing a lightweight UHPC, which would be a promising material for long-span structures.
Carbon foam products are currently manufactured on a commercial scale utilizing a high-pressure autoclave in batch mode. In an effort to increase manufacturing speed and reduce cost, carbon foam products (both panels and aggregates) were produced at atmospheric pressure in a continuous belt kiln. Here, the microstructure, properties, and performance of these materials were characterized and assessed in various applications. Lightweight aggregate was explored for use as a proppant, as well as it use in concrete and asphalt. The thermal conductivity, water permeability, and fire resistance of panels were evaluated, and its performance with respect to screw pullout was compared against conventional building materials. Some interesting performance aspects and potential for future work was revealed. This work was supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).
The design and manufacturing of a solar thermal collector is discussed. The collector has three primary subsystems: concentrator, receiver/fluid loop, and controls. Identical curved reflective columns are utilized in a faceted Fresnel design to support 864 one foot square flat inexpensive second-surface, silvered glass mirrors. The columns are ganged together and rotated through their centers of gravity to provide elevation tracking. The concentrator is supported by a lightweight spaceframe structure which distributes all wind and gravity loads to the base supports. The base of the structure is a track which rotates on wheels mounted on concrete piers. A parallel tube steel heat exchanger is mounted at the concentrator focal area in a well insulated, galvanized steel housing. Two rows of vertical close-packed, staggered tubes connect a mud header and a steam header. Automatic two axis tracking and operational control is provided with a microprocessor based package. Concentrator-mounted shadowbands are the basis for active tracking. A software program provides azimuthal tracking during cloudy periods.
Robots can provide a remote presence in areas that are either inaccessible or too dangerous for humans. However, robots are often limited by their ability to adapt to the terrain or resist environmental factors. The Durable Reconnaissance and Observation Platform (DROP) is a lightweight robot that addresses these challenges with the capability to survive falls from significant heights, carry a useable payload, and traverse a variety of surfaces, including climbing vertical surfaces like wood, stone, and concrete. DROP is manufactured using a combination of rapid prototyping and shape deposition manufacturing. It uses microspine technology to create a new wheel-like design for vertical climbing. To date, DROP has successfully engaged several vertical surfaces, hanging statically without assistance, and traversed horizontal surfaces at approximately 30 cm/s. Unassisted vertical climbing is capable on surfaces up to 85deg at a rate of approximately 25cm*s(sup -1). DROP can also survive falls from up to 3 meters and has the ability to be thrown off of and onto rooftops. Future efforts will focus on improving the microspine wheels, selecting more resilient materials, customizing the controls, and performing more rigorous and quantifiable testing.
Robots have been a valuable tool for providing a remote presence in areas that are either inaccessible or too dangerous for humans. Having a robot with a high degree of adaptability becomes crucial during such events. The adaptability that comes from high mobility and high durability greatly increases the potential uses of a robot in these situations, and therefore greatly increases its usefulness to humans. DROP is a lightweight robot that addresses these challenges with the capability to survive large impacts, carry a usable payload, and traverse a variety of surfaces, including climbing vertical surfaces like wood, stone, and concrete. The platform is crash-proof, allowing it to be deployed in ways including being dropped from an unmanned aerial vehicle or thrown from a large MSL-class (Mars Science Laboratory) rover.
We propose an abstraction-based model checking method which relies on refinement of an under-approximation of the feasible behaviors of the system under analysis. The method preserves errors to safety properties, since all analyzed behaviors are feasible by definition. The method does not require an abstract transition relation to he generated, but instead executes the concrete transitions while storing abstract versions of the concrete states, as specified by a set of abstraction predicates. For each explored transition. the method checks, with the help of a theorem prover, whether there is any loss of precision introduced by abstraction. The results of these checks are used to decide termination or to refine the abstraction, by generating new abstraction predicates. If the (possibly infinite) concrete system under analysis has a finite bisimulation quotient, then the method is guaranteed to eventually explore an equivalent finite bisimilar structure. We illustrate the application of the approach for checking concurrent programs. We also show how a lightweight variant can be used for efficient software testing.