Pub Date : 2026-07-01Epub Date: 2025-12-11DOI: 10.1016/j.cscm.2025.e05682
Imtiaz Iqbal , Waleed Bin Inqiad , Tala Kasim , Svetlana Besklubova , Melak Mohammad Adil , Mujib Rahman
This study investigates the performance of 3D printed concrete incorporating fly ash as a partial cement replacement and develops a machine learning model to predict its mechanical properties. A total of 28 mixtures were prepared with varying fly ash contents (5–15 %), water-to-binder ratios, and superplasticiser dosages. Of these, seven mixes met the requirements for printability in terms of flowability, extrudability, and buildability. Experimental tests were conducted to evaluate compressive strength, flexural strength, water absorption, and sorptivity. Results showed that mixes with 5 % and 7.5 % fly ash achieved improved strength and durability, whereas higher fly ash levels reduced early-age performance due to clinker dilution and slower pozzolanic activity. Microstructural analyses confirmed the presence of C–S–H, portlandite, and ettringite, with fly ash contributing to pore refinement and matrix densification. To enhance predictive capability, a TPE-optimised Extreme Gradient Boosting (TPE-XGB) model was developed using data obtained from laboratory testing. The model achieved excellent accuracy (R² > 0.997) in predicting compressive and flexural strength. A graphical user interface integrating SHAP visualisation was created to provide transparent predictions, supporting practical implementation. The findings highlight the potential of fly ash to improve the sustainability of 3D printed concrete at optimised dosages and demonstrate the value of interpretable machine learning tools in mix design optimisation.
{"title":"Strength characterisation of fly ash blended 3D printed concrete enhanced with explainable machine learning","authors":"Imtiaz Iqbal , Waleed Bin Inqiad , Tala Kasim , Svetlana Besklubova , Melak Mohammad Adil , Mujib Rahman","doi":"10.1016/j.cscm.2025.e05682","DOIUrl":"10.1016/j.cscm.2025.e05682","url":null,"abstract":"<div><div>This study investigates the performance of 3D printed concrete incorporating fly ash as a partial cement replacement and develops a machine learning model to predict its mechanical properties. A total of 28 mixtures were prepared with varying fly ash contents (5–15 %), water-to-binder ratios, and superplasticiser dosages. Of these, seven mixes met the requirements for printability in terms of flowability, extrudability, and buildability. Experimental tests were conducted to evaluate compressive strength, flexural strength, water absorption, and sorptivity. Results showed that mixes with 5 % and 7.5 % fly ash achieved improved strength and durability, whereas higher fly ash levels reduced early-age performance due to clinker dilution and slower pozzolanic activity. Microstructural analyses confirmed the presence of C–S–H, portlandite, and ettringite, with fly ash contributing to pore refinement and matrix densification. To enhance predictive capability, a TPE-optimised Extreme Gradient Boosting (TPE-XGB) model was developed using data obtained from laboratory testing. The model achieved excellent accuracy (R² > 0.997) in predicting compressive and flexural strength. A graphical user interface integrating SHAP visualisation was created to provide transparent predictions, supporting practical implementation. The findings highlight the potential of fly ash to improve the sustainability of 3D printed concrete at optimised dosages and demonstrate the value of interpretable machine learning tools in mix design optimisation.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05682"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788493","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The study explores the deterioration mechanism of basalt fiber-aeolian sand concrete (BF-ASC) under wind-sand erosion (WSE) and compares its performance with ordinary concrete. Experimental analysis was conducted to examine the effects of factors such as attack angle, average wind velocity, sand carrying capacity, sand erosion time, and sand particle size on the erosion of BF-ASC. Three-dimensional blue-light scanning was used to observe surface morphological changes, revealing the distribution of damage during erosion. Scanning electron microscopy (SEM) was employed to examine the effects of microstructural changes on corrosion resistance. The results show that BF-ASC exhibits stronger erosion resistance than ordinary concrete under different attack angles, particularly at a 45° angle, where the mass loss and degree of erosion were significantly lower for BF-ASC than for ordinary concrete. However, under other WSE parameters, the erosion resistance of both concretes was similar, with BF-ASC showing slightly better resistance. The study also reveals multiple mechanisms of WSE. The impact of sand particles causes localized stress concentration, leading to the detachment of surface material and the expansion of microcracks. Shallow angle impacts primarily induce shear, leading to surface deterioration and crack propagation, while larger angle impacts create deep pits, further increasing local material removal. Increased wind velocity and sand particle size significantly exacerbate the erosion process. Erosion rate is strongly influenced by erosion time, with rapid erosion occurring in the early stages (0–8 min), followed by stabilization in the later stages (8–16 min). The findings provide valuable insights into optimizing the durability of concrete structures in wind-sand environments, suggest strategies to enhance concrete erosion resistance, and offer a theoretical basis for the design and maintenance of concrete structures in extreme conditions.
{"title":"Erosion resistance of basalt fiber-aeolian sand concrete under wind-sand erosion: Experimental analysis and mechanisms","authors":"Yu Ye , Tianyu Xie , Tong Guo , Biqin Dong , Jianye Zhao , Jiajia Feng","doi":"10.1016/j.cscm.2025.e05728","DOIUrl":"10.1016/j.cscm.2025.e05728","url":null,"abstract":"<div><div>The study explores the deterioration mechanism of basalt fiber-aeolian sand concrete (BF-ASC) under wind-sand erosion (WSE) and compares its performance with ordinary concrete. Experimental analysis was conducted to examine the effects of factors such as attack angle, average wind velocity, sand carrying capacity, sand erosion time, and sand particle size on the erosion of BF-ASC. Three-dimensional blue-light scanning was used to observe surface morphological changes, revealing the distribution of damage during erosion. Scanning electron microscopy (SEM) was employed to examine the effects of microstructural changes on corrosion resistance. The results show that BF-ASC exhibits stronger erosion resistance than ordinary concrete under different attack angles, particularly at a 45° angle, where the mass loss and degree of erosion were significantly lower for BF-ASC than for ordinary concrete. However, under other WSE parameters, the erosion resistance of both concretes was similar, with BF-ASC showing slightly better resistance. The study also reveals multiple mechanisms of WSE. The impact of sand particles causes localized stress concentration, leading to the detachment of surface material and the expansion of microcracks. Shallow angle impacts primarily induce shear, leading to surface deterioration and crack propagation, while larger angle impacts create deep pits, further increasing local material removal. Increased wind velocity and sand particle size significantly exacerbate the erosion process. Erosion rate is strongly influenced by erosion time, with rapid erosion occurring in the early stages (0–8 min), followed by stabilization in the later stages (8–16 min). The findings provide valuable insights into optimizing the durability of concrete structures in wind-sand environments, suggest strategies to enhance concrete erosion resistance, and offer a theoretical basis for the design and maintenance of concrete structures in extreme conditions.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05728"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921436","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-07-01Epub Date: 2025-12-17DOI: 10.1016/j.cscm.2025.e05716
Fatheali A. Shilar , Dhafer Ali Alqahtani , Mubarakali Shilar , T.M. Yunus Khan
This study examines the growing need for sustainable and thermally efficient lightweight concretes, specifically through the advancement of geopolymer foam concrete (GFC). This novel material integrates industrial red mud (RM) and agricultural corncob ash (CCA) as partial replacements in a fly ash–based binder. This study aims to investigate the issues associated with foam instability, increased water absorption, and reduced mechanical strength that are commonly observed in waste-derived GFC materials. Six mix formulations (GC1–GC6) were developed by adjusting the CCA content from 0 to 250 kg/m³, and their rheological, thermal, mechanical, electrical, and microstructural properties were assessed. The measurement of compressive strength was conducted at both 3 and 28 days, whereas all additional tests were executed on samples that had been cured for 28 days.The findings indicated that the incorporation of moderate amounts of CCA (100–150 kg/m³) led to improvements in foam stability, enhanced thermal insulation properties, and preserved sufficient structural integrity, with GC3 demonstrating the highest 28-day compressive strength of 2.86 MPa. Excessive CCA (GC6) resulted in unstable pore structures, diminished gel formation, increased water absorption (62.7 %), and the lowest strength recorded (1.45 MPa). The thermal conductivity exhibited a reduction from 0.91 to 0.52 W/m·K, while the electrical resistivity demonstrated an increase from 6.1 to 35.2 Ω·m across the various mixes, suggesting enhanced insulating characteristics as the content of CCA increased. SEM–EDS analysis validated the presence of well-structured geopolymer gels in low-to-moderate CCA mixtures, while revealing disrupted matrices at elevated CCA concentrations.The findings of the study indicate that optimized RM–CCA–FA ternary binders are capable of generating lightweight, low-carbon GFC that exhibits enhanced thermal and electrical properties, thereby supporting the development of sustainable construction materials in accordance with the Sustainable Development Goals 9, 11, 12, and 13.
{"title":"Valorization of agricultural and industrial wastes in geopolymer foam concrete, a ternary binder approach using corncob ash, red mud, and fly ash","authors":"Fatheali A. Shilar , Dhafer Ali Alqahtani , Mubarakali Shilar , T.M. Yunus Khan","doi":"10.1016/j.cscm.2025.e05716","DOIUrl":"10.1016/j.cscm.2025.e05716","url":null,"abstract":"<div><div>This study examines the growing need for sustainable and thermally efficient lightweight concretes, specifically through the advancement of geopolymer foam concrete (GFC). This novel material integrates industrial red mud (RM) and agricultural corncob ash (CCA) as partial replacements in a fly ash–based binder. This study aims to investigate the issues associated with foam instability, increased water absorption, and reduced mechanical strength that are commonly observed in waste-derived GFC materials. Six mix formulations (GC1–GC6) were developed by adjusting the CCA content from 0 to 250 kg/m³, and their rheological, thermal, mechanical, electrical, and microstructural properties were assessed. The measurement of compressive strength was conducted at both 3 and 28 days, whereas all additional tests were executed on samples that had been cured for 28 days.The findings indicated that the incorporation of moderate amounts of CCA (100–150 kg/m³) led to improvements in foam stability, enhanced thermal insulation properties, and preserved sufficient structural integrity, with GC3 demonstrating the highest 28-day compressive strength of 2.86 MPa. Excessive CCA (GC6) resulted in unstable pore structures, diminished gel formation, increased water absorption (62.7 %), and the lowest strength recorded (1.45 MPa). The thermal conductivity exhibited a reduction from 0.91 to 0.52 W/m·K, while the electrical resistivity demonstrated an increase from 6.1 to 35.2 Ω·m across the various mixes, suggesting enhanced insulating characteristics as the content of CCA increased. SEM–EDS analysis validated the presence of well-structured geopolymer gels in low-to-moderate CCA mixtures, while revealing disrupted matrices at elevated CCA concentrations.The findings of the study indicate that optimized RM–CCA–FA ternary binders are capable of generating lightweight, low-carbon GFC that exhibits enhanced thermal and electrical properties, thereby supporting the development of sustainable construction materials in accordance with the Sustainable Development Goals 9, 11, 12, and 13.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05716"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921491","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-07-01Epub Date: 2025-12-26DOI: 10.1016/j.cscm.2025.e05733
Kuisheng Liu , Huikai Yuan , Shiyu Zhuang
Mass concrete structures face critical challenges regarding thermal cracking and durability, yet conventional evaluation methods based on standard curing fail to predict material performance under realistic thermal histories. This study systematically investigates the thermo-mechanical behavior of mass concrete containing four ultra-fine supplementary cementitious materials (SCMs): ultra-fine steel slag (USS), ultra-fine limestone powder (ULS), ultra-fine phosphorus slag (UPS), and ground fly ash (GFA). A multi-scale framework was established, integrating hydration kinetics testing, finite element analysis (FEA) for temperature field simulation, and mechanical/durability testing under temperature-matching curing conditions. Numerical and experimental results indicate that USS effectively reduced the early-age hydration heat peak while maintaining long-term strength comparable to fly ash. Conversely, GFA and ULS exacerbated early heat release due to high reactivity and nucleation effects, respectively. Notably, a high replacement level (45 %) of UPS successfully suppressed the initial heat peak through the dilution effect, while the subsequent temperature rise activated its latent reactivity, significantly enhancing late-age compressive strength and chloride resistance. The study confirms that an integrated approach combining numerical simulation and temperature-matching curing offers a more reliable method than conventional screening for selecting SCMs in mass concrete, effectively balancing the competing demands of low early-age heat and high long-term performance.
{"title":"Thermo-mechanical behavior of mass concrete with promising ultra-fine SCMs: A multi-scale experimental and numerical study","authors":"Kuisheng Liu , Huikai Yuan , Shiyu Zhuang","doi":"10.1016/j.cscm.2025.e05733","DOIUrl":"10.1016/j.cscm.2025.e05733","url":null,"abstract":"<div><div>Mass concrete structures face critical challenges regarding thermal cracking and durability, yet conventional evaluation methods based on standard curing fail to predict material performance under realistic thermal histories. This study systematically investigates the thermo-mechanical behavior of mass concrete containing four ultra-fine supplementary cementitious materials (SCMs): ultra-fine steel slag (USS), ultra-fine limestone powder (ULS), ultra-fine phosphorus slag (UPS), and ground fly ash (GFA). A multi-scale framework was established, integrating hydration kinetics testing, finite element analysis (FEA) for temperature field simulation, and mechanical/durability testing under temperature-matching curing conditions. Numerical and experimental results indicate that USS effectively reduced the early-age hydration heat peak while maintaining long-term strength comparable to fly ash. Conversely, GFA and ULS exacerbated early heat release due to high reactivity and nucleation effects, respectively. Notably, a high replacement level (45 %) of UPS successfully suppressed the initial heat peak through the dilution effect, while the subsequent temperature rise activated its latent reactivity, significantly enhancing late-age compressive strength and chloride resistance. The study confirms that an integrated approach combining numerical simulation and temperature-matching curing offers a more reliable method than conventional screening for selecting SCMs in mass concrete, effectively balancing the competing demands of low early-age heat and high long-term performance.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05733"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921564","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This study presents a novel, reinforcement-free prefabricated composite beam system integrating 3D-printed concrete (3DPC) slabs and glued laminated timber (GLT) beams. The system employs an ultra-high-performance concrete (UHPC)-filled notch-screw shear connector to address the interfacial bonding challenge between the two materials. Push-out tests on the connector demonstrated that its load-bearing capacity and slip stiffness increased with notch depth and length, while the shear length ahead of the notch had a minor influence. For the critical 3DPC-UHPC interface, three failure modes were identified, with performance governed by matrix interlayer properties and interface morphology. The X-interface with an original 3DPC surface was optimal, and adding polyoxymethylene fiber further enhanced performance. Connectors with a vertical printing path showed superior performance, with approximately 8 % higher load capacity than those with a horizontal path. Bending tests on composite beams clarified the influence of cross-sectional mesh configuration and printing material. Beams with a transverse mesh exhibited 28.8 % greater initial stiffness than those with a top-surface mesh. Crucially, the system achieved satisfactory structural performance without traditional steel reinforcement, validating the feasibility of the proposed reinforcement-free, prefabricated approach. Finally, predictions for bending stiffness and interface shear capacity based on the gamma method showed good agreement with experimental values.
{"title":"Experimental investigation on the mechanical performance of 3D-printed concrete-glued laminated timber composite beams","authors":"Xiaoyue Zhang , Zhengren Chen , Xinting Zhou , Zheng Li , Xuhong Zhou","doi":"10.1016/j.cscm.2025.e05749","DOIUrl":"10.1016/j.cscm.2025.e05749","url":null,"abstract":"<div><div>This study presents a novel, reinforcement-free prefabricated composite beam system integrating 3D-printed concrete (3DPC) slabs and glued laminated timber (GLT) beams. The system employs an ultra-high-performance concrete (UHPC)-filled notch-screw shear connector to address the interfacial bonding challenge between the two materials. Push-out tests on the connector demonstrated that its load-bearing capacity and slip stiffness increased with notch depth and length, while the shear length ahead of the notch had a minor influence. For the critical 3DPC-UHPC interface, three failure modes were identified, with performance governed by matrix interlayer properties and interface morphology. The X-interface with an original 3DPC surface was optimal, and adding polyoxymethylene fiber further enhanced performance. Connectors with a vertical printing path showed superior performance, with approximately 8 % higher load capacity than those with a horizontal path. Bending tests on composite beams clarified the influence of cross-sectional mesh configuration and printing material. Beams with a transverse mesh exhibited 28.8 % greater initial stiffness than those with a top-surface mesh. Crucially, the system achieved satisfactory structural performance without traditional steel reinforcement, validating the feasibility of the proposed reinforcement-free, prefabricated approach. Finally, predictions for bending stiffness and interface shear capacity based on the gamma method showed good agreement with experimental values.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05749"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921672","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-07-01Epub Date: 2026-01-01DOI: 10.1016/j.cscm.2025.e05750
Jiuhong Fan , Xiuhua Li , Bowen Xiao , Ying Lu , Jin Di , Fengjiang Qin
The application of precast bridge piers is becoming increasingly widespread due to its significant time-saving advantages. To enhance the seismic performance of the bridge piers, ultrahigh-performance concrete (UHPC) jackets was set in the plastic hinge of the precast bridge piers with socket connection. Quasi-static tests were conducted on five specimens to investigate the influence of the height and thickness of the UHPC jacket on the seismic behavior of precast bridge piers. When the UHPC jacket height was too low or the thickness was too great, the plastic hinge region of the pier shifted upward, reducing the ductility and cumulative energy dissipation of the pier, which adversely affected its seismic performance. Based on the numerical analysis results, a bending moment enhancement coefficient was regressed and the dimension design method of UHPC jacket was proposed. This study provides a reference for designing UHPC jackets to enhance the seismic performance of bridge piers.
{"title":"Seismic performance enhancement of precast bridge pier using ultrahigh-performance concrete jacket","authors":"Jiuhong Fan , Xiuhua Li , Bowen Xiao , Ying Lu , Jin Di , Fengjiang Qin","doi":"10.1016/j.cscm.2025.e05750","DOIUrl":"10.1016/j.cscm.2025.e05750","url":null,"abstract":"<div><div>The application of precast bridge piers is becoming increasingly widespread due to its significant time-saving advantages. To enhance the seismic performance of the bridge piers, ultrahigh-performance concrete (UHPC) jackets was set in the plastic hinge of the precast bridge piers with socket connection. Quasi-static tests were conducted on five specimens to investigate the influence of the height and thickness of the UHPC jacket on the seismic behavior of precast bridge piers. When the UHPC jacket height was too low or the thickness was too great, the plastic hinge region of the pier shifted upward, reducing the ductility and cumulative energy dissipation of the pier, which adversely affected its seismic performance. Based on the numerical analysis results, a bending moment enhancement coefficient was regressed and the dimension design method of UHPC jacket was proposed. This study provides a reference for designing UHPC jackets to enhance the seismic performance of bridge piers.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05750"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921674","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-07-01Epub Date: 2025-12-16DOI: 10.1016/j.cscm.2025.e05709
Xiaodong Wang , Guangcheng Long , Fan Wang , Junfeng Wen , Yuting Zhang , Changhe Huang , Ruxia Zhou
The global industrial challenges of massive phosphogypsum (PG) stockpiles, persistent underutilization, and inferior water resistance of conventional gypsum-based materials necessite innovative recycling strategies. Herein, we engineered a phosphogypsum-based composite binders (PBCB) by coupling ground-granulated blast furnace slag (GGBS) and carbide slag (CS) with anhydrous PG (APG) and β-hemihydrate PG (β-HPG). The compressive strength and water resistance of PBCB under air curing and water curing were investigated at 180d. Its phase composition, hydration process, pore structure, and microstructure were explored, followed by an evaluation of its environmental and economic benefits. Results showed that the combination of APG and β-HPG can significantly shortened the setting time of PBCB. Under the synergistic effect of hydration products, the mixture of 70 % APG/10 % β-HPG and 18 % GGBS/2 % CS shows the best performance. After 180d of air curing and water curing, the compressive strength and softening coefficient are 44.5 MPa, 0.83 and 41.9 MPa, 0.89, respectively. Notably, under water curing, the compressive strength decreases by only 4.17 %–10.32 %, while the softening coefficient increases by 6.74 %–12.64 %. In addition, the carbon emissions per unit strength and cost per unit strength are only 21.0 % and 35.7 % of those of ordinary Portland cement, respectively. This work establishes a viable technical pathway for transforming hazardous PG stockpiles (>80 million tons/year globally) into low-carbon sustainable binders.
{"title":"Durable phosphogypsum-based composite binders with ground-granulated blast furnace slag and carbide slag: Performance optimization and environmental assessment","authors":"Xiaodong Wang , Guangcheng Long , Fan Wang , Junfeng Wen , Yuting Zhang , Changhe Huang , Ruxia Zhou","doi":"10.1016/j.cscm.2025.e05709","DOIUrl":"10.1016/j.cscm.2025.e05709","url":null,"abstract":"<div><div>The global industrial challenges of massive phosphogypsum (PG) stockpiles, persistent underutilization, and inferior water resistance of conventional gypsum-based materials necessite innovative recycling strategies. Herein, we engineered a phosphogypsum-based composite binders (PBCB) by coupling ground-granulated blast furnace slag (GGBS) and carbide slag (CS) with anhydrous PG (APG) and β-hemihydrate PG (β-HPG). The compressive strength and water resistance of PBCB under air curing and water curing were investigated at 180d. Its phase composition, hydration process, pore structure, and microstructure were explored, followed by an evaluation of its environmental and economic benefits. Results showed that the combination of APG and β-HPG can significantly shortened the setting time of PBCB. Under the synergistic effect of hydration products, the mixture of 70 % APG/10 % β-HPG and 18 % GGBS/2 % CS shows the best performance. After 180d of air curing and water curing, the compressive strength and softening coefficient are 44.5 MPa, 0.83 and 41.9 MPa, 0.89, respectively. Notably, under water curing, the compressive strength decreases by only 4.17 %–10.32 %, while the softening coefficient increases by 6.74 %–12.64 %. In addition, the carbon emissions per unit strength and cost per unit strength are only 21.0 % and 35.7 % of those of ordinary Portland cement, respectively. This work establishes a viable technical pathway for transforming hazardous PG stockpiles (>80 million tons/year globally) into low-carbon sustainable binders.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05709"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788436","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-07-01Epub Date: 2025-12-10DOI: 10.1016/j.cscm.2025.e05671
Maryam Abazarsa, Tzuyang Yu
Steel corrosion is the main cause responsible for the premature failures of reinforced and prestressed concrete structures (e.g., bridges) around the world. Corrosion detection of steel rebars and tendons using nondestructive testing/evaluation (NDT/E) techniques such as ground-penetrating radar (GPR) have demonstrated to be an effective approach for early warning, while various technical challenges remain unsolved in the data interpretation. This is mainly due to the environmental variation in the field and various corrosion levels and concrete properties in noisy GPR data, making the prediction of steel rebar corrosion very difficult in the field. The objective of this paper is to present our approach on analyzing long-term noisy GPR data to extract subsurface steel rebar’s condition without monitoring environmental variation. Our deep learning approach utilizes a convolutional neural network (CNN) AlexNet model and a proposed Power2Net model to predict the corrosion level of steel rebars in concrete bridge columns from 3834 GPR B-scan images on 186 days over a two-year period. The novelty of our approach is the ability to correlate surface visual images with subsurface GPR B-scan images for subsurface steel rebar corrosion prediction. Seven concrete bridge columns at different corrosion levels (from intact to corroded) were scanned in each inspection. In our approach, AlexNet is used for extracting multi-scale features from the images, while Power2Net is used to predict corrosion levels of steel rebars inside concrete. Three laboratory reinforced concrete specimens with known corrosion levels were used to verify our model. From our parametric study, it is found that an inverse power-law pattern between the size of a filter and the number of filters as a function of neural network layer is the key to efficiently extract essential information from noisy radar images and robustly predict steel rebar corrosion in the long-term. From our results, it is found that our proposed DL approach (AlexNet-Power2Net) can predict the corrosion level of different concrete columns under the influence of long-term environmental variation without any environmental data, demonstrating the consistency and robustness of our approach. The environmental effect on B-scan images was amplified by the corrosion level and manifested by false alarms in our predicted level curves. Optimal initial learning rate and optimal number of epochs were found to be 0.001 and 73, respectively, in our case study. We also found that fine-tuning of weights (or model pretraining) can improve model convergence.
{"title":"A deep learning approach for predicting steel rebar corrosion in concrete bridge columns from two-year noisy GPR B-scan images","authors":"Maryam Abazarsa, Tzuyang Yu","doi":"10.1016/j.cscm.2025.e05671","DOIUrl":"10.1016/j.cscm.2025.e05671","url":null,"abstract":"<div><div>Steel corrosion is the main cause responsible for the premature failures of reinforced and prestressed concrete structures (e.g., bridges) around the world. Corrosion detection of steel rebars and tendons using nondestructive testing/evaluation (NDT/E) techniques such as ground-penetrating radar (GPR) have demonstrated to be an effective approach for early warning, while various technical challenges remain unsolved in the data interpretation. This is mainly due to the environmental variation in the field and various corrosion levels and concrete properties in noisy GPR data, making the prediction of steel rebar corrosion very difficult in the field. The objective of this paper is to present our approach on analyzing long-term noisy GPR data to extract subsurface steel rebar’s condition without monitoring environmental variation. Our deep learning approach utilizes a convolutional neural network (CNN) AlexNet model and a proposed Power2Net model to predict the corrosion level of steel rebars in concrete bridge columns from 3834 GPR B-scan images on 186 days over a two-year period. The novelty of our approach is the ability to correlate surface visual images with subsurface GPR B-scan images for subsurface steel rebar corrosion prediction. Seven concrete bridge columns at different corrosion levels (from intact to corroded) were scanned in each inspection. In our approach, AlexNet is used for extracting multi-scale features from the images, while Power2Net is used to predict corrosion levels of steel rebars inside concrete. Three laboratory reinforced concrete specimens with known corrosion levels were used to verify our model. From our parametric study, it is found that an inverse power-law pattern between the size of a filter and the number of filters as a function of neural network layer is the key to efficiently extract essential information from noisy radar images and robustly predict steel rebar corrosion in the long-term. From our results, it is found that our proposed DL approach (AlexNet-Power2Net) can predict the corrosion level of different concrete columns under the influence of long-term environmental variation without any environmental data, demonstrating the consistency and robustness of our approach. The environmental effect on B-scan images was amplified by the corrosion level and manifested by false alarms in our predicted level curves. Optimal initial learning rate and optimal number of epochs were found to be 0.001 and 73, respectively, in our case study. We also found that fine-tuning of weights (or model pretraining) can improve model convergence.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05671"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145788591","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-07-01Epub Date: 2025-12-15DOI: 10.1016/j.cscm.2025.e05701
Decai Wang , Xiyang Hou , Ziming Liu , Zongyuan Wu , Shi Dong , Dongfa Han
This study proposes a novel shear index-centered design framework for emulsified asphalt cold recycled mixtures (ECRM) to overcome the limitations of the Marshall design method. A comprehensive system was developed by integrating gyratory compaction, Lorentz function-based pore analysis, and Mohr-Coulomb theory, optimizing compaction parameters and mechanical performance. Experimental results indicate that 50 gyrations achieve optimal compaction, reducing emulsified asphalt content by 0.5 % and water demand by 0.6 % compared to the Marshall method, while increasing dry density to 2.116 g/cm³ . A critical innovation of this study lies in the novel, first-time integration of Lorentz-function-based pore analysis and Mohr–Coulomb shear theory for ECRM design. The Lorentz function not only quantifies the similarity of pore distribution between gyratory compaction specimens and field cores (peak void volume: 0.28 mm³ vs. 0.25 mm³, deviation 12 %) and also provides a micro-scale benchmark for shear-parameter optimization. Based on this benchmark, shear parameters (cohesion c and internal friction angle φ) are innovatively derived from indirect tensile strength (ITS) and unconfined compressive strength (UCS) via simplified Mohr-Coulomb-derived formulas, which avoids the tedious triaxial tests required by traditional methods. Laboratory validations confirm superior performance, including a dynamic stability of 4557 cycles/mm, a freeze-thaw split ratio of 77.6 %, and a low-temperature failure strain of 2160 . Field validations across four expressway projects (e.g., Beijing-Hong Kong-Macao) demonstrate early-stage structural performance and over 10 years of service without rutting or significant cracking. This integrated design system establishes a quantitative correlation between "microscopic pores and macroscopic shear performance", provides theoretical support for the design and construction of ECRM, and promotes the standardized application of cold recycling technology.
{"title":"Optimizing shear performance of emulsified asphalt cold recycled mixtures via gyratory compaction: Mechanisms, design, and field validation","authors":"Decai Wang , Xiyang Hou , Ziming Liu , Zongyuan Wu , Shi Dong , Dongfa Han","doi":"10.1016/j.cscm.2025.e05701","DOIUrl":"10.1016/j.cscm.2025.e05701","url":null,"abstract":"<div><div>This study proposes a novel shear index-centered design framework for emulsified asphalt cold recycled mixtures (ECRM) to overcome the limitations of the Marshall design method. A comprehensive system was developed by integrating gyratory compaction, Lorentz function-based pore analysis, and Mohr-Coulomb theory, optimizing compaction parameters and mechanical performance. Experimental results indicate that 50 gyrations achieve optimal compaction, reducing emulsified asphalt content by 0.5 % and water demand by 0.6 % compared to the Marshall method, while increasing dry density to 2.116 g/cm³ . A critical innovation of this study lies in the novel, first-time integration of Lorentz-function-based pore analysis and Mohr–Coulomb shear theory for ECRM design. The Lorentz function not only quantifies the similarity of pore distribution between gyratory compaction specimens and field cores (peak void volume: 0.28 mm³ vs. 0.25 mm³, deviation 12 %) and also provides a micro-scale benchmark for shear-parameter optimization. Based on this benchmark, shear parameters (cohesion c and internal friction angle φ) are innovatively derived from indirect tensile strength (ITS) and unconfined compressive strength (UCS) via simplified Mohr-Coulomb-derived formulas, which avoids the tedious triaxial tests required by traditional methods. Laboratory validations confirm superior performance, including a dynamic stability of 4557 cycles/mm, a freeze-thaw split ratio of 77.6 %, and a low-temperature failure strain of 2160 <span><math><mrow><mi>μ</mi><mi>ε</mi></mrow></math></span>. Field validations across four expressway projects (e.g., Beijing-Hong Kong-Macao) demonstrate early-stage structural performance and over 10 years of service without rutting or significant cracking. This integrated design system establishes a quantitative correlation between \"microscopic pores and macroscopic shear performance\", provides theoretical support for the design and construction of ECRM, and promotes the standardized application of cold recycling technology.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05701"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921438","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Vibration is a critical procedure in the production of cementitious materials to reduce porosity and improve compaction. However, the vibration energy of poker (inserted-type) vibrators exhibits spatial attenuation, which leads to pore distributive heterogeneity and results in uneven mechanical behavior of the material. The current study experimentally investigates the heterogeneity issue and quantifies the relevant efficient compaction zone (ECZ) for a single poker vibrator. Experimental results demonstrate that energy transmission of poker vibration becomes stable at 20 s and forms the ECZ with only 53.9 % coverage. The study confirms that certain difference of insertion depths between two adjacent vibrators can effectively improve the ECZ coverage and solve the corresponding heterogeneity problem. Subsequently, it formulates equations to determine the optimal depth difference and to develop a modified vibration mode. Compared to the conventional operation modes, the presented mode reduces the vertical porosity deviation from 2.46 % to 0.90 % and decreases the overall specimen porosity from 4.27 % to 2.47 %. And it achieves over 95 % ECZ coverage. The findings and the proposed method have applications in promoting the precise vibration control for the on-site cementitious material production.
{"title":"Pore distributive heterogeneity of cementitious materials by poker vibration: Quantification and modification","authors":"Zhiming Yu, Yimiao Huang, Wei Dong, Xiaokuan Zhao, Fang Wang, Guowei Ma","doi":"10.1016/j.cscm.2025.e05720","DOIUrl":"10.1016/j.cscm.2025.e05720","url":null,"abstract":"<div><div>Vibration is a critical procedure in the production of cementitious materials to reduce porosity and improve compaction. However, the vibration energy of poker (inserted-type) vibrators exhibits spatial attenuation, which leads to pore distributive heterogeneity and results in uneven mechanical behavior of the material. The current study experimentally investigates the heterogeneity issue and quantifies the relevant efficient compaction zone (ECZ) for a single poker vibrator. Experimental results demonstrate that energy transmission of poker vibration becomes stable at 20 s and forms the ECZ with only 53.9 % coverage. The study confirms that certain difference of insertion depths between two adjacent vibrators can effectively improve the ECZ coverage and solve the corresponding heterogeneity problem. Subsequently, it formulates equations to determine the optimal depth difference and to develop a modified vibration mode. Compared to the conventional operation modes, the presented mode reduces the vertical porosity deviation from 2.46 % to 0.90 % and decreases the overall specimen porosity from 4.27 % to 2.47 %. And it achieves over 95 % ECZ coverage. The findings and the proposed method have applications in promoting the precise vibration control for the on-site cementitious material production.</div></div>","PeriodicalId":9641,"journal":{"name":"Case Studies in Construction Materials","volume":"24 ","pages":"Article e05720"},"PeriodicalIF":6.6,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145921441","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}