Skip to main content
SpringerLink
Log in

Behavior of a high-volume fly ash fiber-reinforced cement composite toward magnesium sulfate: a long-term study

  • Technical Paper
  • Published:
Innovative Infrastructure Solutions Aims and scope Submit manuscript

Abstract

Sulfate attack is one of the severe concerns for concrete's durability in sulfate-rich soil, groundwater, and the marine environment. The ingress of dissolved sodium and (or) magnesium sulfate in concrete leads to the formation of expansive products such as gypsum, ettringite, brucite, and magnesium-silicate-hydrate (M–S–H), causing extensive cracking and disintegration of concrete based on the severity of the attack. The consequence of ingress of magnesium sulfate is more severe than sodium sulfate. The present article aims to assess the long-term behavior of a novel cement composite incorporating 80% class-F fly ash (F-FA) and 20% ordinary Portland cement with varying volume fractions of polypropylene fibers exposed to 5% magnesium sulfate solution for up to two years. The compressive strength, weight, and volume changes of the specimens measure these effects. The mixes with higher volume fractions of PP fibers undergo a 40% reduction in compressive strength, 6.7% weight gain, and 3.5% volume change at two years. The morphological features revealed through SEM images and EDX analysis find the formation of M–S–H, brucite, gypsum, ettringite traces, and unreacted F-FA. The outcomes of this study encourage the utilization of F-FA to a much higher volume to help reduce the carbon footprint and promote sustainability.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Tahwia AM, Fouda RM, AbdElrahman M, Youssf O (2022) Long-term performance of concrete made with different types of cement under severe sulfate exposure. Materials 16:240. https://doi.org/10.3390/ma16010240

    Article  Google Scholar 

  2. Ouyang C, Nanni A, Chang WF (1988) Internal and external sources of sulfate ions in portland cement mortar: two types of chemical attack. Cem Concr Res 18:699–709. https://doi.org/10.1016/0008-8846(88)90092-0

    Article  Google Scholar 

  3. Zhao G, Li J, Shi M, Fan H, Cui J, Xie F (2020) Degradation mechanisms of cast-in-situ concrete subjected to internal-external combined sulfate attack. Constr Build Mater 248:118683. https://doi.org/10.1016/j.conbuildmat.2020.118683

    Article  Google Scholar 

  4. Ragoug R, Metalssi OO, Barberon F, Torrenti J-M, Roussel N, Divet L, d’Espinose De Lacaillerie J-B (2019) Durability of cement pastes exposed to external sulfate attack and leaching: physical and chemical aspects. Cem. Concr. Res. 116:134–145. https://doi.org/10.1016/j.cemconres.2018.11.006

    Article  Google Scholar 

  5. Wang R, Zhang Q, Li Y (2022) Deterioration of concrete under the coupling effects of freeze-thaw cycles and other actions: a review. Constr Build Mater 319:126045. https://doi.org/10.1016/j.conbuildmat.2021.126045

    Article  Google Scholar 

  6. Wang K, Guo J, Wu H, Yang L (2020) Influence of dry-wet ratio on properties and microstructure of concrete under sulfate attack. Constr Build Mater 263:120635. https://doi.org/10.1016/j.conbuildmat.2020.120635

    Article  Google Scholar 

  7. Zhang Z, Zhou J, Yang J, Zou Y, Wang Z (2020) Understanding of the deterioration characteristic of concrete exposed to external sulfate attack: insight into mesoscopic pore structures. Constr Build Mater 260:119932. https://doi.org/10.1016/j.conbuildmat.2020.119932

    Article  Google Scholar 

  8. Gu Y, Dangla P, Martin R-P, OmikrineMetalssi O, Fen-Chong T (2022) Modeling the sulfate attack induced expansion of cementitious materials based on interface-controlled crystal growth mechanisms. Cem Concr Res 152:106676. https://doi.org/10.1016/j.cemconres.2021.106676

    Article  Google Scholar 

  9. Gu Y, Martin R-P, OmikrineMetalssi O, Fen-Chong T, Dangla P (2019) Pore size analyzes of cement paste exposed to external sulfate attack and delayed ettringite formation. Cem Concr Res 123:105766. https://doi.org/10.1016/j.cemconres.2019.05.011

    Article  Google Scholar 

  10. Liu P, Chen Y, Wang W, Yu Z (2020) Effect of physical and chemical sulfate attack on performance degradation of concrete under different conditions. Chem Phys Lett 745:137254. https://doi.org/10.1016/j.cplett.2020.137254

    Article  Google Scholar 

  11. Bondar D, Nanukuttan S (2022) External sulfate attack on alkali-activated slag and slag/fly ash concrete. Buildings 12:94. https://doi.org/10.3390/buildings12020094

    Article  Google Scholar 

  12. Nayak DK, Abhilash PP, Singh R, Kumar R, Kumar V (2022) Fly ash for sustainable construction: a review of fly ash concrete and its beneficial use case studies. Clean Mater 6:100143. https://doi.org/10.1016/j.clema.2022.100143

    Article  Google Scholar 

  13. Rida L, Alaoui AH (2022) Effect of high volume fly ash and curing temperature on delayed ettringite formation. Mater Today Proc 58:1285–1293. https://doi.org/10.1016/j.matpr.2022.02.110

    Article  Google Scholar 

  14. Juenger MC, Siddique R (2015) Recent advances in understanding the role of supplementary cementitious materials in concrete. Cem Concr Res 78:71–80

    Article  Google Scholar 

  15. Tang SW, Yao Y, Andrade C, Li ZJ (2015) Recent durability studies on concrete structure. Cem Concr Res 78:143–154

    Article  Google Scholar 

  16. Lothenbach B, Scrivener K, Hooton RD (2011) Supplementary cementitious materials. Cem Concr Res 41:1244–1256. https://doi.org/10.1016/j.cemconres.2010.12.001

    Article  Google Scholar 

  17. Herath C, Gunasekara C, Law DW, Setunge S (2020) Performance of high volume fly ash concrete incorporating additives: a systematic literature review. Constr Build Mater 258:120606. https://doi.org/10.1016/j.conbuildmat.2020.120606

    Article  Google Scholar 

  18. Tian W, Gao F (2020) Damage and degradation of concrete under coupling action of freeze-thaw cycle and sulfate attack. Adv Mater Sci Eng 2020:1–17. https://doi.org/10.1155/2020/8032849

    Article  Google Scholar 

  19. Golewski GL (2022) Combined effect of coal fly ash (CFA) and nanosilica (NS) on the strength parameters and microstructural properties of eco-friendly concrete. Energies 16:452. https://doi.org/10.3390/en16010452

    Article  Google Scholar 

  20. Golewski GL (2023) Concrete composites based on quaternary blended cements with a reduced width of initial microcracks. Appl Sci 13:7338. https://doi.org/10.3390/app13127338

    Article  Google Scholar 

  21. Golewski GL (2023) Assessing of water absorption on concrete composites containing fly ash up to 30% in regards to structures completely immersed in water. Case Stud Constr Mater 19:e02337. https://doi.org/10.1016/j.cscm.2023.e02337

    Article  Google Scholar 

  22. Golewski GL (2023) Mechanical properties and brittleness of concrete made by combined fly ash, silica fume and nanosilica with ordinary portland cement. AIMS Mater Sci 10:390–404. https://doi.org/10.3934/matersci.2023021

    Article  Google Scholar 

  23. Golewski GL (2023) The effect of the addition of coal fly ash (CFA) on the control of water movement within the structure of the concrete. Materials 16:5218. https://doi.org/10.3390/ma16155218

    Article  Google Scholar 

  24. Quan X, Wang S, Liu K, Zhao N, Xu J, Xu F, Zhou J (2021) The Corrosion resistance of engineered cementitious composite (ECC) containing high-volume fly ash and low-volume bentonite against the combined action of sulfate attack and dry-wet cycles. Constr Build Mater 303:124599. https://doi.org/10.1016/j.conbuildmat.2021.124599

    Article  Google Scholar 

  25. Zhao N, Wang S, Wang C, Quan X, Yan Q, Li B (2020) Study on the durability of engineered cementitious composites (ECCs) containing high-volume fly ash and bentonite against the combined attack of sulfate and freezing–thawing (F–T). Constr Build Mater 233:117313. https://doi.org/10.1016/j.conbuildmat.2019.117313

    Article  Google Scholar 

  26. Singh LP, Ali D, Tyagi I, Sharma U, Singh R, Hou P (2019) Durability studies of nano-engineered fly ash concrete. Constr Build Mater 194:205–215. https://doi.org/10.1016/j.conbuildmat.2018.11.022

    Article  Google Scholar 

  27. Yang J, Zeng L, He X, Su Y, Li Y, Tan H, Jiang B, Zhu H, Oh S-K (2021) Improving durability of heat-cured high volume fly ash cement mortar by wet-grinding activation. Constr Build Mater 289:123157. https://doi.org/10.1016/j.conbuildmat.2021.123157

    Article  Google Scholar 

  28. Saxena A, Sulaiman SS, Shariq M, Ansari MA (2023) Experimental and analytical investigation of concrete properties made with recycled coarse aggregate and bottom ash. Innov Infrastruct Solut 8:197. https://doi.org/10.1007/s41062-023-01165-y

    Article  Google Scholar 

  29. Irmawaty R, Caronge MA, Tjaronge MW, Abdurrahman MA, Ahmad SB (2023) Compressive strength and corrosion behavior of steel bars embedded in concrete produced with ferronickel slag aggregate and fly ash: an experimental study. Innov Infrastruct Solut 8:200. https://doi.org/10.1007/s41062-023-01162-1

    Article  Google Scholar 

  30. Elahi MMA, Shearer CR, Naser Rashid Reza A, Saha AK, Khan MNN, Hossain MM, Sarker PK (2021) Improving the sulfate attack resistance of concrete by using supplementary cementitious materials (SCMs): a review. Constr Build Mater 281:122628. https://doi.org/10.1016/j.conbuildmat.2021.122628

    Article  Google Scholar 

  31. Zhang J, Zheng Q, Cheng M (2021) Study on mechanical properties and air-void structure characteristics of hybrid fiber fly ash concrete under sulfate attack. Mater Res Express 8:105504. https://doi.org/10.1088/2053-1591/ac2d6e

    Article  Google Scholar 

  32. Liu J, Li A, Yang Y, Wang X, Yang F (2022) Dry–wet cyclic sulfate attack mechanism of high-volume fly ash self-compacting concrete. Sustainability 14:13052. https://doi.org/10.3390/su142013052

    Article  Google Scholar 

  33. Mansoori A, Behfarnia K (2021) Evaluation of mechanical and durability properties of engineered cementitious composites exposed to sulfate attack and freeze-thaw cycle. Asian J Civ Eng 22:417–429. https://doi.org/10.1007/s42107-020-00322-3

    Article  Google Scholar 

  34. Huang J, Wang Z, Li D, Li G (2022) Effect of nano-SiO2/PVA fiber on sulfate resistance of cement mortar containing high-volume fly ash. Nanomaterials 12:323. https://doi.org/10.3390/nano12030323

    Article  Google Scholar 

  35. Hanif Khan M, Zhu H, Ali Sikandar M, Zamin B, Ahmad M, Sabri M (2022) Effects of various mineral admixtures and fibrillated polypropylene fibers on the properties of engineered cementitious composite (ECC) based mortars. Materials 15:2880. https://doi.org/10.3390/ma15082880

    Article  Google Scholar 

  36. Jaworska-Wędzińska M, Jasińska I (2021) Durability of mortars with fly ash subject to freezing and thawing cycles and sulfate attack. Materials 15:220. https://doi.org/10.3390/ma15010220

    Article  Google Scholar 

  37. Kim J, Qudoos A, Jakhrani S, Lee J, Kim S, Ryou J-S (2019) Mechanical properties and sulfate resistance of high volume fly ash cement mortars with air-cooled slag as fine aggregate and polypropylene fibers. Materials 12:469. https://doi.org/10.3390/ma12030469

    Article  Google Scholar 

  38. Görhan G, Kavasoğlu E (2022) Effect of fly ash on mechanical and durability properties of mortar containing microfibers with different length. Eur J Environ Civ Eng 26:1283–1299. https://doi.org/10.1080/19648189.2019.1707713

    Article  Google Scholar 

  39. Liu J, Zang S, Yang F, Zhang M, Li A (2022) Fracture mechanical properties of steel fiber reinforced self-compacting concrete under dry-wet cycle sulfate attack. Buildings 12:1623. https://doi.org/10.3390/buildings12101623

    Article  Google Scholar 

  40. Bankir MB, KorkutSevim U (2020) Performance optimization of hybrid fiber concretes against acid and sulfate attack. J Build Eng 32:101443. https://doi.org/10.1016/j.jobe.2020.101443

    Article  Google Scholar 

  41. Gong L, Yu X, Liang Y, Gong X, Du Q (2023) Multi-scale deterioration and microstructure of polypropylene fiber concrete by salt freezing. Case Stud Constr Mater 18:e01762. https://doi.org/10.1016/j.cscm.2022.e01762

    Article  Google Scholar 

  42. Hussein TA, Dheyaaldin MH, Mosaberpanah MA, Ahmed YMS, Mohammed HA, Omer RR, Hamid SM, Alzeebaree R (2023) Chemical resistance of alkali-activated mortar with nano silica and polypropylene fiber. Constr Build Mater 363:129847. https://doi.org/10.1016/j.conbuildmat.2022.129847

    Article  Google Scholar 

  43. Zhao N, Wang S, Quan X, Liu K, Xu J, Xu F (2022) Behavior of fiber reinforced cementitious composites under the coupled attack of sulfate and dry/wet in a tidal environment. Constr Build Mater 314:125673. https://doi.org/10.1016/j.conbuildmat.2021.125673

    Article  Google Scholar 

  44. YavuzBayraktar O, Salem TaherEshtewı S, Benli A, Kaplan G, Toklu K, Gunek F (2021) The Impact of RCA and fly ash on the mechanical and durability properties of polypropylene fiber-reinforced concrete exposed to freeze-thaw cycles and MgSO4 with ANN modeling. Constr Build Mater 313:125508. https://doi.org/10.1016/j.conbuildmat.2021.125508

    Article  Google Scholar 

  45. Ren J, Lai Y (2021) Study on the durability and failure mechanism of concrete modified with nanoparticles and polypropylene fiber under freeze-thaw cycles and sulfate attack. Cold Reg Sci Technol 188:103301. https://doi.org/10.1016/j.coldregions.2021.103301

    Article  Google Scholar 

  46. Wei Y, Chai J, Qin Y, Li Y, Xu Z, Li Y, Ma Y (2021) Effect of fly ash on mechanical properties and microstructure of cellulose fiber-reinforced concrete under sulfate dry–wet cycle attack. Constr Build Mater 302:124207. https://doi.org/10.1016/j.conbuildmat.2021.124207

    Article  Google Scholar 

  47. Ma H, Yi C, Wu C (2021) Review and outlook on durability of engineered cementitious composite (ECC). Constr Build Mater 287:122719. https://doi.org/10.1016/j.conbuildmat.2021.122719

    Article  Google Scholar 

  48. Sugandhini HK, Nayak G, Shetty KK, Kudva LP (2023) the durability of high-volume fly ash-based cement composites with synthetic fibers in a corrosive environment: a long-term study. Sustainability 15:11481. https://doi.org/10.3390/su151511481

    Article  Google Scholar 

  49. IS 516 (1959): Method of Tests for Strength of Concrete. Bureau of Indian Standards: Chandigarh, India

  50. Aye T, Oguchi CT, Takaya Y (2010) Evaluation of sulfate resistance of portland and high alumina cement mortars using hardness test. Constr Build Mater 24:1020–1026. https://doi.org/10.1016/j.conbuildmat.2009.11.016

    Article  Google Scholar 

  51. Shen Y, Li Q, Huang B, Liu X, Xu S (2022) Effects of PVA fibers on microstructures and hydration products of cementitious composites with and without fly ash. Constr Build Mater 360:129533. https://doi.org/10.1016/j.conbuildmat.2022.129533

    Article  Google Scholar 

Download references

Acknowledgements

The authors credit the inventors, Dr. Bhanumathidas and N. Kalidas, Directors, INSWAREB, Vishakhapatnam, Andhra Pradesh, India, for allowing the authors to work on no-aggregate concrete and offering technical and technological support at various stages of the study. They hold the IP rights of no-aggregate concrete.

Funding

This research received no external funding and The APC was funded by Manipal Academy of Higher Education, Manipal 576104, Karnataka, India.

Author information

Authors and Affiliations

  1. Department of Civil Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, Karnataka, 576104, India

    H. K. Sugandhini, Gopinatha Nayak, Kiran K. Shetty & Laxman P. Kudva

Authors
  1. H. K. Sugandhini
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Gopinatha Nayak
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kiran K. Shetty
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Laxman P. Kudva
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

SHK and GN contributed to Conceptualization; SHK contributed to methodology, investigation resources, writing—original draft preparation, writing—review and editing and supervision; SHK, KKS, and LKP contributed to data curation; GN contributed to visualization; GN and KKS contributed to project administration; All authors have read and agreed to the published version of the manuscript.

Corresponding author

Correspondence to Laxman P. Kudva.

Ethics declarations

Conflict of interest

The authors declare no conflict of interest.

Ethical approval

This paper neither was published nor is under review elsewhere.

Informed consent

All the authors are aware of this paper.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sugandhini, H.K., Nayak, G., Shetty, K.K. et al. Behavior of a high-volume fly ash fiber-reinforced cement composite toward magnesium sulfate: a long-term study. Innov. Infrastruct. Solut. 8, 328 (2023). https://doi.org/10.1007/s41062-023-01298-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s41062-023-01298-0

Keywords

Search

Navigation