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To cite this article: Y. Zhang, G. Ma, Y. Liu & Z. Li (2015) Mix design for thermal insulation
concrete using waste coal gangue as aggregate, Materials Research Innovations, 19:sup5,
S5-878-S5-884, DOI: 10.1179/1432891714Z.0000000001212
Article views: 82
Download by: [University of California, San Diego] Date: 21 April 2016, At: 00:34
Mix design for thermal insulation concrete
using waste coal gangue as aggregate
Y. Zhang, G. Ma, Y. Liu and Z. Li*
The purpose of this paper is to prepare a new type of thermal insulation concrete (TIC) which
possesses good bearing capacity with excellent thermal insulation. An orthogonal experimental
design method was used in this paper to study the influence of the substitution ratio of CG and
the contents of GHB, NS and UFS on the compressive strength of concrete, thermal conductivity
coefficient, construction performance, and dry density. Test results show that the comprehensive
strength of concrete reaches the optimal when the substitution ratio of CG is 30%, the GHB
content is 134 kg/m3, the proportions of NS and UFS are 0.4% and 5% of binding material
Downloaded by [University of California, San Diego] at 00:34 21 April 2016
amount, respectively. For the optimal mix proportion, the thermal conductivity coefficient and
compressive strength of the concrete are 0.41 W m1 k1 and 37.7 MPa, respectively.
Keywords: Thermal insulation concrete, Glazed hollow bead, Coal gangue, Nano-silica, Orthogonal experimental design method
Introduction (NA), and found that CG, within a certain range, does
not reduce the compressive strength of concrete. Also,
Compared with normal concrete, lightweight aggregate the interface structure of high-quality CG aggregate is
concrete has the advantages reduced mass one1,2 and similar to that of ordinary aggregate. Li et al. 8 found
heat preservation.3 It can reduce weight of the structure, that the drying shrinkage of CG concrete tends to be
reduce the foundation load and improve the efficiency stable at the later stage of hydration. Yang and Yu9
of transportation, loading and construction. The achieved 49 MPa compressive strength for lightweight
reduced mass can significantly increase the overall econ- concrete made with spontaneous combustion CG.
omic efficiency of the structure. Thus, it can be seen that the preparation of concrete by
Zhang et al.s4 study showed that glazed hollow bead using CG has some promising qualities. Coal gangue has
(GHB), if mixed in appropriate proportion, can fill the the characteristics of light weight and high strength. It can
voids between cement, coarse aggregate and fine aggre- be mixed in concrete as aggregate through simple crush-
gate so that pore structure of concrete is evenly distribu- ing. The method of using CG as the coarse aggregate is
ted. Owing to the closed surface of GHB, a large more fully understood and economically viable method
number of cavities are formed, which block the heat con- of using CG in concrete. However, previous research
duction channels in concrete to improve the thermal has mainly focussed on the normal concrete mixed with
resistance of concrete and reduce the density of concrete. CG. Very few studies exist about applying CG to high-
In recent years, China has done much research and performance concrete.
development work in coal gangue (CG) utilization. This research utilised CG to replace natural coarse
However, CG has not been widely realised as a natural aggregate partially in TIC, and nano-silica (NS) and
resource yet. Some studies have focussed on the use of ultra-fine slag (UFS) to improve mechanically and con-
CG as a natural resource. Some researchers focussed on struction performances of coal gangue thermal insulation
the comprehensive utilization of CG, and in turn, some concrete (CGTIC). Coal gangue thermal insulation con-
progress has been made in the development of new- crete can utilise CG waste as much as possible under
concrete materials by using CG. the premise of not affecting the performance of concrete.
Chen5 mixed multiple sets of concrete with different
mix designs by using CG without screening, tested con-
crete at different ages, and discussed strength evolution
and failure mechanism. Zhang et al. 6 showed that Materials and experimental methods
sprayed concrete made with fine CG particles has good
mechanical properties and workability. Zhang et al. 7 Materials
used certain content of CG to replace natural aggregate CG as aggregate
Different types of CG in this study are from Jincheng
open-pit mine in Shanxi Province, China. The prep-
College of Architecture and Civil Engineering, Taiyuan University of aration of CG coarse aggregate was prepared through
Technology, PR China crushing, sieving and grading processes. The properties
*Corresponding author, email 215215zy@163.com of CG are shown in Table 1.
Item CG
Item Color Granularity (mm) Density (kg m3) Thermal conductivity (W m1 K1) Absorptivity (%)
Table 4 The basic formulation of CGTIC Table 7 Range analysis of orthogonal experiment, the result
of slump
NA S C FA Water-cement WRA/
(kg) (kg) (kg) (kg) ratio C Slump
No. A B C D Blank column
1160 580 450 50 045 003
1
K 170 191 191 178 178
2
K 180 182 191 178 178
3
K 188 175 175 180 180
Table 5 L16(45) orthogonal factor level table
4
K 178 167 157 177 177
Factor R 18 24 34 3 3
Lever A B C D
Compressive
strength (MPa)
(A) NS (B) GHB (C ) CG (D) UFS Blank Thermal conductivity Slump Dry density
No. (%) (%) (%) (%) column 7 days 28 days (W m1 k1) (mm) (kg m3)
Factor Si n1 i
S F Significance Critical value
Table 9 Range analysis of orthogonal experiment, the result Table 11 Range analysis of orthogonal experiment, the
of 7-day compressive strength result of 28-day compressive strength
1
K 242 262 290 258 263 1
K 336 344 381 346
2
K 285 261 277 260 269 2
K 353 342 364 339
3
K 283 257 256 259 257 3
K 364 337 336 337
4
K 227 258 215 258 248 4
K 309 339 281 338
R 58 05 75 02 21 R 55 07 10 09
Downloaded by [University of California, San Diego] at 00:34 21 April 2016
calculation method is shown in equations (1) and (2). GHB did not absorb moisture from the slurry.
Therefore, the influence of GHB content on the initial
1 slump of CGTIC had reduced. Despite the relatively
P= (x1 + x2 + + x16 )2 (1)
16 small amount of NS, its dispersive effect has a great
role in promoting a fluidity of concrete. In the early
1 4
hydration of cement particles, some ions and groups are
Si = (K i )2 P (2)
4 j=1 j electrically polarised because of their precipitation, and
flocculation structure is produced to make part of water
In this paper, F = S e, S
i /S e = Se /3, and compare with a wrapped inside. For CGTIC including NS, part of the
certain critical value Fa (a = 001,005,010) to judge nanoparticles are adsorbed on the surface of cement par-
whether the influence of a factor is significant. When ticles to remove flocculation structure and release the
F > F001 , a strong influence is expressed by using **. parcel of moisture. This part of released water improves
When F001 > F > F005 , the significant influence is the fluidity of CGTIC. Slump began to decline with an
expressed by using *. When F005 F > F010 , a notice- increase in NS content. This is because of the increased
able influence is expressed by using . When F < F01 , amount of NS leading to an increase in total specific
the least influence is expressed by using . surface area of gel material, which needed more water
to increase its liquidity.
The analysis of influence of various factors on slump The analysis of variance for orthogonal experiment
Table 7 shows that the optimal mixing proportion of results on the slump of CGTIC is shown in Table 8. It
CGTIC on slump is either A3&B1&C1&D3 or can be seen from Table 8 that the factors affecting
A3&B1&C2&D3. Figure 2 shows that the influences of slump are prioritised as C > B > A > D, which is consist-
various factors on the slump of CGTIC are ordered in ent with the result from range analysis. Contents of CG,
the sequence of the importance as CG > GHB > NS > GHB and NS have marked an influence on the slump
UFS. while the UFS content has little influence.
Coal gangue is in a loose state, it has large specific
surface area and more internal pores. Thus, CGTIC
needs more water to wet the larger surface area and to Influence of various factors on the 7-day compressive
fill the abundant pores.12 Consequently, the fluidity of strength
CGTIC decreases, resulting in increased water demand. Table 9 shows that the optimal mix design for 7-day com-
The higher the CG amount, the greater is the water pressive strength of CGTIC is A2&B1&C1&D2. Figure 3
demand. Although the water absorption of GHB is shows that the factors affecting 7-day compressive
around 30%, because of the pre-wetting technology strength of CGTIC are prioritised as CG > NS >
adopted in the mixing process of CGTIC, the pre-wet GHB > UFS.
Table 10 Variance analysis of orthogonal experiment, the result of 7-day compressive strength
3 The influence of various factors on 7-day compressive 4 Influence of various factors on 28-day compressive
strength strength
Table 12 Variance analysis of orthogonal experiment, the result of 28-day compressive strength
Factor Si n1 i
S F Significance Critical value
Ca(OH)2 in cement, and the desired effect of interface- A4)&B4&(C3 or C4)&D2. Figure 5 shows that the
enhancement is achieved. factors affecting thermal conductivity of CGTIC are
Dangling bonds are formed because of the lack of adja- prioritised as GHB > CG > UFS > NS.
cent atoms around the surface of nanomaterial. With a The internal pores of GHB are spherical and closed to
great desaturation, they are easy to combine with other each other. The air in pores has no heat convection; these
atoms. In addition, the surface of nanomaterial has solid pores can block heat transfer channels to reduce the
atoms with a lot more atomic number than of those in thermal conductivity coefficient of CGTIC. Unlike the
material with ordinary size. Thus, nanomaterial has normal bubbles introduced by foaming agent and air-
very high surface energy and chemical activity. Nano- entraining agent, the bubbles introduced by GHB
silica has small particles, high surface energy, low cannot be decomposed and reduced in the cement with
polymerization degree of [SiO4]4 ion and very high ash
Downloaded by [University of California, San Diego] at 00:34 21 April 2016
1
K 037 040 038 037 036
2
K 036 037 037 035 035
3
K 037 035 035 036 036
4
K 036 033 035 036 036 5 Influence of various factors on thermal conductivity
R 001 007 003 002 001
coefficient
Table 14 Variance analysis of orthogonal experiment, the result of thermal conductivity coefficient
Factor Si n1 i
S F Significance Critical value
Material usage
NA (kg) CG (kg) Sand (kg) C (kg) GHB (kg) FA (kg) UFS (kg) NS (kg) Water (kg) WRA (kg)