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Development of building materials based on a high content of fly ash and polycondensation products from Chinese heat and power plants

Andrii Bieliatynskyi
Andrii Bieliatynskyi
, 
Shilin Yang
Shilin Yang
, 
Valerii Pershakov
Valerii Pershakov
, 
Meiyu Shao
Meiyu Shao
 et 
Mingyang Ta
Mingyang Ta
   | 24 nov. 2022
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Publié en ligne: 24 nov. 2022
Pages: 270 - 288
Reçu: 16 mars 2022
Accepté: 09 oct. 2022
DOI: https://doi.org/10.2478/msp-2022-0025
Mots clés
© 2022 Andrii Bieliatynskyi et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

Calcium hydroxide binding process. SAFA, Supplement acetone-formaldehyde additive
Calcium hydroxide binding process. SAFA, Supplement acetone-formaldehyde additive

Results of tests on the strength of samples made of a mixture of normal temperature

Content of additive (%) W/C (%) Strength indicators (MPa)
Ash Acetone-formaldehyde additive In 3 days hardening at 25°C In 7 days hardening at 25°C In 28 days hardening at 25°C
Bend Compression Bend Compression Bend Compression
Reference composition 0.56 2.3 9.8 3.8 16 5 22
Without additives 0.15 0.51 2.7 12 4.1 22 5.5 27.5
20 - 0.54 1.3 8 3.2 14 6 20.5
20 0.15 0.50 2.6 10 3.4 16.8 5.3 24
30 - 0.56 1.2 6.5 3 12.8 4.8 19.5
30 0.15 0.51 2.4 9.5 3.2 15.6 5.2 22.5
40 - 0.56 0.8 5.4 2.6 9.6 5.8 18
40 0.15 0.51 1.9 7 2.7 12.8 5 19.5

Results of tests on the strength of samples made of a mixture of an elevated temperature

Content of additive (%) W/C (%) Strength indicators, MPa, in a day hardening at 50°C
Ash SAFA In 3 days hardening at 25°C In 7 days hardening at 25°C In 28 days hardening at 25°C
Bend Compression Bend Compression Bend Compression
Reference composition 0.58 2.1 11 4 17 5.2 23.5
Without additives 0.15 0.53 3.4 13.2 4.8 18.8 6 30.5
20 - 0.56 1.9 9 3.5 15.8 5 21.5
20 0.15 0.52 3.4 12.8 4.2 19 5.6 26.5
30 - 0.57 1.7 8 3.2 14 4.9 20
30 0.15 0.53 3 10 3.6 16.8 5.4 24
40 - 0.57 1.5 5 2.8 13.5 4.9 18.5
40 0.15 0.53 2.4 8 3 14.5 5.2 20.5

The results of the determination of water resistance

Content of additive (%) Pressure at which water filtration began, MPa in concrete brands Water resistance grades, concrete brands
Ash Acetone-formaldehyde additive 200 300 400 200 300 400
0 0 0.35 0.35 0.4 B-4 B-4 B-4
0.15 0.76 0.75 0.8 B-8 B-8 B-8
20 0 0.26 0.2 0.25 B-2 B-2 B-2
0.15 0.55 0.6 0.65 B-6 B-6 B-6
30 0 0.15 0.2 0.2 B-2 B-2 B-2
0.15 0.55 0.6 0.6 B-6 B-6 B-6
40 0 0.15 0.15 0.2 B-2 B-2 B-2
0.15 0.45 0.5 0.55 B-6 B-6 B-6

Strength gained with time

Content of the components of the cement paste (%) Strength of a sample of cement stone, MPa in a day
Cement Ash Acetone-formaldehyde resins 1 3 7 28
100 - - 31 52 72 78
100 - 0.15 35 65 83 88
90 10 - 25 44 70 75
90 10 0.15 33 53 78 80
80 20 - 22 43 60 64
80 20 0.15 31 52 72 79
70 30 - 20 37 49 60
70 30 0.15 29 47 67 76
60 40 - 18 29 39 50
60 40 0.15 25 42 54 62

Compositions of heavy concretes

Concrete grade
Brand Cement (g/cm3) Sand (g/cm3) Crushed stone (g/cm3) Water (g/cm3)
200 280 630 1,300 150
300 370 610 1,250 175
400 430 580 1,160 200

Normal density and setting time of cement paste

Content of the components of the cement paste (%) Normal density of the cement paste (g/cm3) Setting time (h:min)
Cement Ash Acetone-formaldehyde resins Start Finish
100 - - 27.5 1:30 7:15
100 - 0.15 23.5 2:15 6:00
90 10 - 28.0 2:00 8:25
90 10 0.15 26.0 2:40 6:45
80 20 - 29.0 2:40 8:45
80 20 0.15 27.0 2:55 7:00
70 30 - 30.0 2:55 8:55
70 30 0.15 27.5 3:15 7:20
60 40 - 30.5 3:20 9:15
60 40 0.15 28.0 3:35 7:35

The experimental results

Concrete brand Strength indicators of concrete, ordinary concrete (numerator) and ash concrete (denominator)
After steaming Over 28 days of curing
200 14.8/12.6 19.6/19.2
300 22.4/19.4 29.8/29
400 28.1/26.5 39.5/39.1

Workability of mortar mixes of the same mobility

Content of additive (%) W/C (%) Mobility, cm (numerator)/cone spread, mm (denominator)
Ash Acetone-formaldehyde additive 0 min 30 min 60 min 90 min 120 min 135 min
At normal temperature
Reference mixture 0.56 4.3/141 3.8/134 3.4/125 3.0/118 - -
Without additives 0.15 0.51 4.5/143 4.0/139 3.6/132 3.3/127 3.0/122 -
20 - 0.54 4.2/142 3.8/138 3.5/130 3.2/125 2.9/120 -
30 - 0.55 4.0/140 3.7/135 3.5/128 3.2/123 3.0/119 -
40 - 0.55 3.8/138 3.6/132 3.4/126 3.1/121 2.8/118 -
20 0.15 0.50 4.2/141 3.8/137 3.5/132 3.3/128 3.0/122 -
30 0.15 0.51 4.0/140 3.7/136 3.4/130 3.1/126 2.9/121 -
40 0.15 0.51 3.8/139 3.6/135 3.3/129 3.0/124 2.8/119 -
At 50°C
0 min 15 min 30 min 45 min 60 min 75 min
Reference mixture 0.58 4.0/140 3.5/128 3.0/121 - - -
Without additives 0.15 0.53 4.1/140 3.7/133 3.2/126 2.9/120 - -
20 - 0.56 4.1/141 3.8/135 3.5/130 3.2/125 - -
30 - 0.57 3.9/139 3.6/135 3.4/129 3.1/124 - -
40 - 0.57 3.8/138 3.5/133 3.1/126 2.8/120 - -
20 0.15 0.52 4.2/142 3.9/137 3.6/134 3.3/129 3.0/123 -
30 0.15 0.53 4.0/140 3.6/136 3.3/133 3.0/128 2.8/122 -
40 0.15 0.53 3.8/139 3.5/135 3.2/131 2.9/124 - -

Indicators of the workability of the mortar mix

Content of additive (%) W/C (%) Mobility, cm (numerator)/cone spread, mm (denominator)
Ash SAFA 0 min 30 min 60 min 90 min 120 min 150 min 180 min 210 min
At normal temperature
Reference mixture 0.56 4.3/142 3.8/129 3.4/125 3.0/118 - - - -
Without additives 0.15 0.56 5.5/160 5.2/155 4.7/148 4.3/140 3.9/132 3.5/125 3.0/119 -
20 - 0.56 5.2/155 5.1/152 5.0/150 4.8/147 4.2/140 3.8/132 3.5/125 3.0/120
30 - 0.56 4.8/149 4.6/147 4.5/145 4.2/142 3.8/136 3.4/129 3.0/122 -
40 - 0.56 4.6/147 4.5/145 4.4/143 4.0/140 3.6/133 3.3/127 3.0/120 -
20 0.15 0.56 6.8/170 6.7/168 6.6/165 6.3/163 6.0/160 5.5/154 5.0/149 4.2/140
30 0.15 0.56 6.3/167 6.1/165 5.9/163 5.6/160 5.3/156 5.0/150 4.4/143 3.8/135
40 0.15 0.56 5.6/165 5.5/163 5.3/161 5.0/158 4.7/155 4.2/147 3.8/142 3.2/134
Ash SAFA W/C (%) 0 min 15 min 30 min 45 min 60 min 75 min 90 min
At 50°C
Without additives 0.15 0.58 4.0/140 3.5/128 3.0/121 - - - -
20 - 0.58 5.0/155 4.5/150 4.0/145 3.5/130 3.0/125 - -
30 - 0.58 4.5/142 4.2/138 3.8/135 3.3/130 - - -
40 - 0.58 4.2/140 3.8/135 3.3/132 3.0/128 - - -
20 0.15 0.58 6.0/158 5.5/152 4.7/147 4.2/141 3.6/134 3.5/134 3.2/129
30 0.15 0.58 5.6/156 5.1/150 4.7/145 4.2/137 3.6/134 3.2/128 2.9/122
40 0.15 0.58 5.4/154 5.0/148 4.5/142 4.0/135 3.4/131 3.0/124 -

Strength of ash concrete

Ash content in concrete mix (%) Content of acetone-formaldehyde additive (%) Compressive strength of concrete brands (MPa)
200 300 400
0 0 20.3 30.2 40.5
0.1 22.5 34.9 47.5
0.15 24.8 36.5 50.2
0.2 21 30 39.6
20 0 15.9 24.5 32.5
0.1 17.8 28.7 38.1
0.15 19.2 31 40
0.2 14.7 22.7 31.7
30 0 14.5 22 30
0.1 16.5 25.6 35.7
0.15 17.9 27.5 38
0.2 13.1 20.7 29.5
40 0 12.5 18.3 24.5
0.1 13.7 19.8 28.7
0.15 14.5 21 30.2
0.2 11.7 17.8 23.5

Chemical composition of ashes

Basic oxides Coal ash (%) Shale ash (%) Peat ash (%)
Anthracite Stone Brown Siliceous Calcified
Si2O3 16–50 22–60 31–58 20–60 42 15
Al2O3 5–37 15–43 20–45 5–20 16 10
Fe2O3 5–40 3–32 2–45 2–10 17 15
CaO Up to 3 Up to 5 Up to 50 10–15 18 50

Cement activity

Hardening age (days) 3 7 28
Brand Compression (MPa) Bending (MPa) Compression (MPa) Bending (MPa) Compression (MPa) Bending (MPa)
500 20.5 1.2 27.2 6.0 50.2 6.1
400 15.9 3.0 24.2 4.8 39.8 5.2

Determination of the strength of samples made of a mixture of normal temperature

Content of additive (%) W/C (%) Strength indicators (MPa)
Ash SAFA In 3 days hardening at 25°C In 7 days hardening at 25°C In 28 days hardening at 25°C
Bend Compression Bend Compression Bend Compression
Reference composition 0.58 1.8 8.8 2.4 13 3.9 19.2
Without additives 0.15 0.52 2 10.2 2.8 15.9 4.4 24.2
20 - 0.57 1.3 7 1.8 11.8 3.3 18
20 0.15 0.51 1.5 8 2.2 13.5 3.8 22
30 - 0.58 1.0 5.7 1.6 10 3 17
30 0.15 0.53 1.3 7.2 2 11.5 3.2 20.5
40 - 0.58 0.8 5.2 1.3 6.8 2.8 15
40 0.15 0.53 1 5.3 1.7 8.7 3 18
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