Herein, a three-dimensional numerical model based on computational fluid dynamics (CFD) for fresh concrete is developed to predict the slump and slump flow. Fresh concrete is considered as a non-Newtonian fluid, and its rheological behaviour is characterised by the Bingham and Herschel-Bulkley (H-B) models, respectively. Experiments are also conducted to validate the reliability and accuracy of this model. Through parametric investigations, the influence mechanisms of relevant factors on the flow characteristics of fresh concrete are analysed and discussed. The results show that the model predictions agree well with the experimental results. The predicted results obtained using the H-B rheological model are more accurate compared to the Bingham model, with average relative errors of 1.73 %, 2.03 % and 3.95 % for slump, slump flow and T₅₀₀, respectively. The flowability of fresh concrete is negatively correlated with power index, yield stress and consistency, while it is positively correlated with density. Grey relational analysis indicates that density has the greatest effect on the results of slump and slump flow, followed by yield stress and consistency, and finally the power index. The CFD-based numerical model presented in this study provides an important approach for better understanding the flow behaviour of fresh concrete from a rheological perspective.

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When serving in the marine environment, reinforced concrete structures are prone to be attacked by chloride ingress, which generally co-occurs with varying humidity and temperature changes. Therefore, considering the interaction between moisture transport and heat transfer, and their individual and coupling effects on chloride transport, this paper presents a novel numerical modelling framework for chloride penetration in concrete under different environmental conditions. In this framework, a novel thermal conductivity model and temperature-depended chloride binding isotherms are also developed, considering the heterogeneous characteristics of concrete. The proposed model is validated against a series of experimental data. By assuming the cyclic humidity and temperature boundary conditions as trigonometric type, this study further discusses the effect of average value, amplitude value and period length of cyclic environmental changes on the chloride transport in concrete. The results indicate that variation in humidity and temperature averages can alter the peak values of chloride content but have less effect on the chloride penetration depth. However, the increased humidity amplitude could significantly promote both the peaks and the penetration depths due to intensive chloride convection caused by moisture transport. This paper is supposed to provide a better understanding of chloride penetration in concrete under a realistic engineering environment.

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Early-age cracking risk induced by autogenous deformation is high for cementitious materials of low water-binder ratios. The autogenous deformation, viscoelastic properties, and stress evolution are three important factors for understanding and quantifying the early-age cracking risk. This paper systematically reviewed the experimental and modelling techniques of the three factors. It is found that the Temperature Stress Testing Machine is a unified experimental method for all these three factors, with a strain-controlled mode for stress evolution, hourly-repeated loading scheme for viscoelastic properties, and free condition for autogenous deformation. Such unified method provides basis for developing various models. By coupling a hydration model for volume fractions of hydrates, a homogenization model for upscaling of viscoelastic properties, and capillary pressure theory for self-desiccation shrinkage, a unified model directly mapping the mix design to the early-age stress can be constructed, which can help optimize the mix design to reduce the early-age cracking risk.

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This review provides a comprehensive analysis of the fatigue behaviour of cementitious materials, focusing on the characterisation, modelling, and mechanisms underlying their fatigue properties. It begins with a detailed exploration of how material composition and loading conditions influence fatigue performance, along with the underlying mechanisms that govern fatigue fracture processes. The review also synthesises current advanced experimental methods for characterising fatigue damage evolution, highlighting significant achievements and methodological innovations. It also examines theoretical approaches, summarising prominent models and emerging theories that deepen the understanding of fatigue behaviour in cementitious materials. Meanwhile, the paper reviews computational techniques based on fracture mechanics, damage mechanics, statistical analysis, machine learning algorithms and multiscale modelling, assessing their potential to improve the accuracy of fatigue predictions. Lastly, the review identifies crucial research gaps and outlines future directions, particularly in understanding fatigue-related coupling mechanisms to enhance the fatigue resistance and durability of cementitious materials.

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Vascular self-healing concrete (SHC) has great potential to mitigate the environmental impact of the construction industry by increasing the durability of structures. Designing concrete with high initial mechanical properties by searching a specific arrangement of vascular structure is of great importance. Herein, an automatic optimization method is proposed to arrange vascular configuration for minimizing the adverse influence of vascular system through a reinforcement learning (RL) approach. A case study is carried out to optimize a concrete beam with 3 pores (representing a vascular network) positioned in the beam midspan within a design space of 40 possibilities. The optimization is performed by the interaction between RL agent and Abaqus simulation environment with the change of target properties as a reward signal. The results illustrates that the RL approach is able to automatically enhance the vascular arrangement of SHC given the fact that the 3-pore structures that have the maximum target mechanical property (i.e., peak load or fracture energy) are accessed for all of the independent runs. The RL optimization method is capable of identifying the structure with high fracture energy in the new optimization task for 4-pore concrete structure.

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Cenospheres are low-density and hollow microspheres derived from coal-fired power plant fly ash waste. This study aims to prepare ultra-light-weight (<1000 kg/m³ wet density) concrete using fly ash cenospheres (FAC). To begin with, FAC's shell thickness and the water absorption and desorption were characterized. A mixing procedure was designed to avoid the segregation between the FAC and cement slurry. FAC can affect the rheological properties of fresh mixture over time through absorption and desorption of free water. The presented ultra-light-weight concrete has several advantages compared to the ones prepared using foaming methods. First, shrinkage is significantly reduced due to FAC's internal restraint and curing effects. Secondly, it has good mechanical performance, especially in bending and is more environmentally friendly due to use of less cement. X-ray computed tomography illustrates that FAC ultra-light-weight concrete has smaller pores of more uniform size compared with those prepared using foaming methods. X-Ray diffraction, thermal gravimetry-derivative thermal gravimetry, fourier-transform infrared spectroscopy and scanning electron microscopy are employed for the hydration products and microstructure characterization. Outcomes prove that FAC can combine well with the cement matrix, and react with calcium hydroxide to produce C-A-S-H through pozzolanic reaction.

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This study investigates the size effect on the compressive strength of foamed concrete at the mesoscale level combining X-ray computed tomography (X-CT) and a discrete lattice model. Image segmentation techniques and X-CT were employed to obtain virtual specimens comprising hydrated cement paste and air voids. The lineal-path function and pore size distribution was used to characterise the air void structure. A two-dimensional lattice fracture model of foamed concrete considering different wet densities was established. The model was verified experimentally at a wet density of 700 kg/m³ and then used to predict the strengths of specimens with wet densities of 600 and 800 kg/m³. Square and rectangular specimens (slenderness ratio = 2) with widths of 10, 20, 40, 70.7, and 100 mm were investigated. Results show that the air void structure significantly influences the observed size effect on the compressive strength in the investigated size range. A random forest regressor was used to predict the compressive strength of the foamed concrete; the regressor yielded satisfactory results. Finally, existing analytical size effect models were used to fit the simulated strength. Although good fitting was achieved, special attention should be given to the applicable range and physical meaning of fitted empirical parameters.

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The production of low-emission additive manufactured cementitious composites using functionalized rock powders offers promising mechanical properties and significantly reduces cement consumption. The effect of powder functionalization on the rheological properties of the mixture remains unclear, so this study investigated how mechanical and chemical functionalization of granite powder waste affects the viscoelastic properties of a cementitious mixture for additive manufacturing. Compression tests were used to track stress-strain changes over time, while Vane and slug tests measured yield stress in mixes with 20 % and 40 % cement replaced by natural (NGP), sieved (SGP), and carbonated granite powder (CGP). The results showed that all three powders (NGP, SGP, and CGP) increased yield stress compared to the reference mix, with CGP having the smallest effect. The functionalization of granite powder may enable the creation of desirable viscoelastic mixtures using sustainable materials. We observed that functionalizing granite powder (SGP and CGP) accelerated changes in the mixture rheological properties, with yield stress increasing by up to 33 %, while NGP showed minimal impact, similar to the reference mix. Differences between the Vane and Slug test results were also identified and their limitations described.@en

This paper presents a state-of-the-art review on the application of additive manufacturing (AM) in self-healing cementitious materials. AM has been utilized in self-healing cementitious materials in three ways: (1) concrete with 3D-printed capsules/vasculatures; (2) 3D concrete printing (3DCP) with fibers or supplementary cementitious materials (SCMs); and (3) a combination of (1) and (2). 3D-printed capsules/vascular systems are the most extensively investigated, which are capable of housing larger volumes of healing agents. However, due to the dimension restraints of printers, most of the printed vasculatures/capsules are in small scale, making them difficult for upscaling. Meanwhile, 3DCP shows great potential to lower the environmental footprint of concrete construction. Incorporation of fibers and SCMs helps improve the autogenous healing performance of 3DCP. Besides, 3D-printed concrete with hollow channels as the vasculature could further improve the autonomous healing and scalability of self-healing cementitious materials. Finally, possible directions for future research are discussed.

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3D printed polymeric reinforcement has been found able to improve the ductility of cementitious materials. However, due to the hydrophobic nature of commonly used 3D printing polymers, the bonding strength between the 3D printed polymers and cementitious matrix is extremely weak, which potentially hinders the mechanical performance of the reinforced composites. This work aims to improve the bonding properties by applying surface modifications on the 3D printed reinforcement, and eventually enhance the mechanical performance of the reinforced cementitious composites. Three types of surface coatings ingredients: epoxy resin (EP), sand sprinkled epoxy (SA) and short steel fibers sprinkled epoxy (SF) were used. Pull-out experiments are performed to study the bonding properties of the 3D printed reinforcement with different coatings. Then, uniaxial tensile and four-point-bending experiments are used to investigate the mechanical performance of the reinforced cementitious composites. A lattice type numerical model is applied to simulate the pull-out and tensile tests. The pull-out experiments indicate that the SA and SF reinforcement achieved approximately two times higher bonding strength than the uncoated and EP reinforcement. The tensile and flexural results suggest that the cementitious composites with SA and SF reinforcement achieved significantly better ductility (manifested by strain-hardening and deflection-hardening behavior) than the composites with uncoated and EP reinforcement. The numerical simulation results highly agree with the experimental findings, and further confirmed that the improved reinforcement-mortar bonding strength is the determinative factor that enhanced the composites mechanical performance. The findings of this work suggest that the sand and steel fiber surface coatings can effectively enhance the ductility of cementitious composites reinforced by 3D printed polymers.@en

The Stiffness Damage Test (SDT), a cyclic test in compression, is considered as a reliable tool for assessing concrete structures affected by ASR. Depending on the extent of ASR damage in concrete, loading levels up to 40% of the compressive strength may contribute to increasing internal damage during testing. Nevertheless, previous research found that no additional damage was induced by the SDT. This confirmed the non-destructive character of the SDT making it valid to determine the compressive strength on the same test specimens following the SDT. However, other research suggests that loading levels above 15% of the compressive strength could lead to load-induced damage in the first load cycle. The implication of the non-destructive character and the loading level of the SDT needs more attention, especially when testing anisotropically ASR-damaged concrete structures. This paper thus presents a critical evaluation of the non-destructive character of the SDT by utilizing Acoustic Emission (AE) measurements. The SDT was used to evaluate an ASR affected concrete structure after 60 years in use. Several cores from cantilever slabs were extracted enabling damage assessment of the concrete structure in use. AE allowed to measure crack occurrence with a higher accuracy. Therefore, the critical load level could be more accurately identified using AE. The magnitude of enhancing internal damage during the SDT is related to the extent of ASR. From this study it can be concluded that the non-destructive character of the stiffness damage test depends the critical load level in relation to the internal degree of damage, which can be determined by means of Acoustic Emission.

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In the race to achieve global climate neutrality, carbon intensive industries like the clinker and cement industry are required to decarbonize rapidly. The environmental impacts related to potential transition pathways to low-carbon systems can be evaluated using prospective life cycle assessment (pLCA). This study conducts a pLCA for future global clinker production, integrating long-term transition pathways from the IMAGE integrated assessment model (IAM) to maintain global consistency. It systematically modifies the ecoinvent v3.9.1 database using the Python library premise to create future database versions representing future clinker production embedded in a future economy according to a 3.5°C-baseline, a 2°C-compliant and a 1.5°C-compliant scenario. Our study indicates that climate change impacts of clinker production may decrease from about 1.03 kg CO₂-eq/kg clinker in 2020 to 0.94 (3.5°C-baseline), 0.20 (2°C-compliant), and 0.16 (1.5°C-compliant) kg CO₂-eq/kg clinker in 2060 for the global average. This corresponds to a 10% (3.5°C-baseline), 81% (2°C-compliant) and 84% (1.5°C-compliant) decrease by 2060 compared to 2020. Under these scenarios, global clinker production alone would require 5%–11% of the remaining end-of-century carbon budget for the 2 °C and 1.5 °C-target, respectively. While the climate change impacts are substantially reduced, our study also indicates that the transition pathways shift the burden towards other impact categories, such as ionizing radiation, ozone depletion, material resources and land use. Developing IAM-compatible scenarios for more product groups helps to increase the coherence of pLCA studies. As this study is based on an IAM heavily reliant on carbon capture and storage and bioenergy, future research should explore the effects of different technology pathways and alternative mitigation strategies.

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Crystalline admixture (CA) is an effective self-healing agent for mortar. However, the effects of crack parameters (i.e. crack width and cracking age) and the service environment on the self-healing behavior of CA-containing mortar are not well understood. Herein, the self-healing behavior of mortar containing a self-developed CA was assessed by testing strength recovery, impermeability recovery, and crack closure in pre-cracked specimens. Three initial crack widths (0.2, 0.3, and 0.4 mm), five cracking ages (3, 7, 14, 28, and 56 days), and four external exposure conditions (humidity chamber, air exposure, water immersion, and wet-dry cycles) are investigated. Furthermore, the influence of different external conditions on the healing products at the region of crack and the pore structure of hardened paste containing CA are studied. The results show that adding 4.54% CA into mortar allows rapid healing of 300 μm-wide cracks. Although wider cracks (400 μm) are more difficult to heal, the sorptivity coefficients of the mortars with 400 μm-wide cracks after healing decrease. When the cracks are produced at an earlier age, the pre-cracked specimens have higher recovery ratios of strength and impermeability after healing, and the specimens pe-cracked at a later age still have acceptable compressive strengths after healing. The analysis shows that the strengths and impermeabilities of pre-cracked mortars containing CA exposed to the four external conditions are all recovered. The best self-healing performance is observed for the specimens exposed to water immersion and wet-dry cycles conditions. Somewhat less good self-healing was observed in the specimens exposed to humid chamber condition, while the worst self-healing performance was in the specimens exposed to air exposure condition. This study provides a theoretical basis for the application of novel CAs in cement-based materials.

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Engineered cementitious composite (ECC) is widely employed in engineering due to its high toughness and ductility. The Interfacial Transition Zone (ITZ) between the fibers and the matrix plays a vital role in influencing the strength and durability of ECC. This study introduces a numerical method to simulate fiber pull-out behaviors, specifically the fiber debonding and slipping. A birth-death method is proposed to account for the mechanical transition from fiber debonding stage to slipping stage. The contributions of various phases in the ITZ are explicitly considered. Furthermore, nanoindentation tests and Backscattered Electron (BSE) imaging were conducted to determine the microstructures of ITZ and local mechanical properties of each phase within the ITZ. A series of fiber pullout experiments with polyvinyl alcohol (PVA) fibers were conducted to calibrate and validate the model. Subsequently, the validated model was employed to explore the influence of w/c ratios, fiber orientations and bonding properties on the interfacial behavior. The microstructure-informed model proposed herein effectively predicts fiber pull-out behavior, facilitating a thorough exploration of fracture mechanisms throughout the pull-out process, and serves as the basis for multiscale modeling of ECC.

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Auxetic cementitious cellular composites (ACCCs) exhibit desirable mechanical properties (e.g., high fracture resistance and energy dissipation), due to their unique deformation characteristics. In this study, a new type of cementitious auxetic material, referred to as peanut shaped ACCC, has been designed and subsequently architected using additive manufacturing techniques. Two peanut shaped ACCCs specimens with different pseudo-minor axes have been tested under uniaxial compression with Digital Image Correlation (DIC) to assess their compressive behavior, peak strength, Poisson's ratio, and energy dissipation capacity. Additionally, cyclic tests were conducted to investigate their compressive resilience properties, further elucidated through microstructural analysis using a digital optical microscope. The mechanical test results were also compared with those of previously developed elliptical-shaped ACCCs. Furthermore, a numerical model was used to simulate the mechanical behavior of peanut shaped ACCCs under uniaxial compression, and showed a good agreement with the experimental data. The auxetic behavior observed in peanut shaped ACCCs arises from the rotation of sections facilitated by fiber bridging at the ligament of adjacent holes within the cementitious unit cell. In comparison to elliptical-shaped ACCCs, peanut shaped ACCCs can exhibit a slightly more negative Poisson's ratio and mitigate stress concentration. The reduction of stress concentration enables peanut shaped ACCCs to dissipate substantial energy, showcasing enhanced ductility and toughness. In cyclic tests, peanut shaped ACCCs exhibit superior recoverable deformation elasticity, attributed to robust fiber bridging capacity. The exceptional mechanical properties exhibited by peanut shaped ACCCs offer a scalable solution for developing energy-absorbent and multifunctional cementitious materials for smart infrastructure.

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This study employs a lattice fracture model to simulate static and fatigue fracture behaviour of Interfacial Transition Zone (ITZ) at microscale and mortar at mesoscale. The heterogeneous microstructure of ITZ and mesostructure of mortar are explicitly considered in the models. The initial step involves calibrating and validating the microscopic model of the ITZ through micro-cantilever bending tests. Subsequently, this validated ITZ model serves as a constitutive law to simulate the fracture behavior of mortar at the mesoscale using an uncoupled upscaling method. The influence of microstructural features, such as w/c ratio and microscopic roughness, on the fracture behaviour of ITZ is investigated. Moreover, the effect of ITZ properties and stress level on the fracture performance and fatigue damage evolution of mortar is also studied. The simulation results for both the ITZ and mortar demonstrate good agreement with experimental results. The proposed two models provide insights into the fracture mechanisms and fatigue damage evolution in cementitious materials subjected to static and cyclic loadings.

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Self-healing concrete using encapsulated healing agent has shown great potential in enhancing concrete durability. However, the capsules are expensive to make and can lower the mechanical properties of concrete. In this study, a new type of manufactured aggregate that employs waste-derived fly ash cenosphere as a carrier of healing agent (SH-CS) was designed and produced. The effect of SH-CS incorporation on hydration, engineering properties and self-healing efficiency of cement mortar was systematically evaluated, with a special focus on self-healing mechanism through the analysis of the mineral composition of the healing product. The results indicate that the prepared SH-CS has good stability in and compatibility with cement mortar. The addition of SH-CS has small influence on the fresh properties of cement mortar and less negative effect on compressive strength at the hardened stage compared to the existing study. By replacing 3 wt.% of fine aggregate with SH-CS, up to 71% of the crack opening area of mortar specimens with a crack width of about 0.3 mm was self-healed after 28 days of water exposure. The self-healing behaviour of SH-CS led to a maximal 41% drop in water adsorption and contributed to the recovery of flexural strength. The healing products precipitated on the fracture surface were mainly composed of amorphous C-S-H and Calcite. It can be estimated that incorporating SH-CS in concrete would result in only a moderate (∼29%) rise in cost for C40 concrete.

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High-strength engineered cementitious composites (ECC) typically require higher cement content, which is negative from the sustainability point of view. To alleviate this problem, herein a low-cost and eco-friendly high-strength ECC (with a compressive strength of over 100 MPa) was developed, and diatomite was used to replace a small amount of cement. An appropriate amount of diatomite was found to improve the compressive strength, tensile strength and first cracking strength of ECC, but at the expense of part of the strain capacity (still all higher than 2.9%). Furthermore, the high pozzolanic activity and specific surface area of diatomite also increased the autogenous shrinkage, but reduced the drying shrinkage of ECC due to its internal curing effect. The incorporation of diatomite improved the pore structure of ECC, consumed more Ca(OH)_2, and enhanced the hydration degree of the mixture. In the end, the economic and environmental benefits of diatomite-modified ECC were also evaluated, and the cost, non-renewable energy demand, and global warming potential of ECC with 3% diatomite were reduced compared to plain ECC by 12.9, 15.1, and 13.3%, respectively. The developed high-strength ECC is therefore a low-cost and eco-friendly alternative to the traditional one.

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A novel highly compressible auxetic cementitious composite (ACC) is developed in this work. Contrary to conventional cementitious materials, such as plain concrete and fiber reinforced concrete, the ACC shows strain-hardening behavior under uniaxial compression: the stress continuously increases with strain up to approximately 40 % strain. On one hand, in the early compression stage, the ACC exhibit highly recoverable deformability of 10 % strain under cyclic loading (20 times higher than the constituent cementitious material). In addition, the ACC shows fatigue damage until the stiffness/strength and energy dissipation plateau values are reached after 500 cycles. At 2.5 % strain amplitude, the plateau stiffness/strength is approximately 120 MPa/3 MPa, while these values are only 25 MPa/1.2 MPa at 5 % strain amplitude. In contrast, the energy dissipation plateau of the ACC is independent from the amplitude and remains at 0.05 J/cm3. On the other hand, due to the strain-hardening behavior, the ACC exhibits significantly improved energy dissipation capacity compared to both the conventional cementitious materials and the auxetic frame. This behavior is achieved by a tailored composite action: integrating cementitious mortar with 3D printed thermoplastic polyurethane (TPU) auxetic frame. A rotating-square auxetic mechanism was designed for the TPU frame for the ACC to achieve the tailored cracking behavior. The horizontal ACC cells enable large deformability by enlarging the crack width under the confinement of the auxetic frame, while the vertical cells work as stiffening phase to ensure load resistance. Owing to the outstanding mechanical properties, the ACC shows great potential to be applied in engineering practice where high compressive deformability is required, for instance yielding elements for squeezing tunnel linings.

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Temperature Stress Testing Machine (TSTM) is a universal testing tool for many properties relevant to early-age cracking of cementitious materials. However, the complexity of TSTMs require heavy lab work and thus hinders a more thorough parametric study on a range of cementitious materials. This study presents the development and validation of a Mini-TSTM for efficiently testing the autogenous deformation (AD), viscoelastic properties, and their combined results, the early-age stress (EAS). The setup was validated through systematic tests of EAS, AD, elastic modulus, and creep. Besides, the heating/cooling capability of the setup was examined by tests of coefficient of thermal expansion by temperature cycles. The results of EAS correspond well to that of AD, which qualitatively validates the developed setup. To quantitatively validate the setup, a classical viscoelastic model was built, based on the scenario of a 1-D uniaxial restraint test, to predict the EAS results with the tested AD, elastic modulus, and creep of the same cementitious material as the input. The predicted EAS matched the testing results of Mini-TSTM with good accuracy in 6 different cases. The viscoelastic model also provided quantitative explanations for why variations in early AD do not influence the EAS results. The testing and modelling results together validate the developed Mini-TSTM setup as an efficient tool for studying early-age cracking of cementitious materials. At the end, the potential limitations of the Mini-TSTM are discussed and its applicability for concrete with aggregate size up to 22 mm is demonstrated.

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