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Related Concept Videos

Pozzolans01:21

Pozzolans

470
Pozzolans are siliceous or aluminous materials blended with Portland cement. They interact with the calcium hydroxide produced during the hydration of Portland cement and contribute to improved strength and durability of concrete. The pozzolanic activity, a measure of a pozzolan's effectiveness, is typically assessed using the strength activity index, as defined in ASTM C 618-93, which calculates the ratio of the compressive strength of cement mixtures with and without pozzolan.
Fly ash is...
470
Additives and Fillers in Concrete01:29

Additives and Fillers in Concrete

323
Additives and fillers are integral to enhancing the properties of concrete. Pozzolans and blast-furnace slag are additives or admixtures due to their reactions with calcium hydroxide released during cement hydration. Fillers, which are finely ground and similar in fineness to Portland cement, improve concrete attributes such as workability density, and reduce capillary bleeding or cracking. Some fillers possess hydraulic properties or participate in benign reactions within the cement paste.
The...
323
Portland Cement01:21

Portland Cement

590
Portland cement is the essential binding ingredient in concrete, made from finely ground materials including lime, iron, silica, and alumina. Lime is derived primarily from limestone, marble, marl, seashells, and clays, which also supply iron and alumina, while silica is sourced from sand, chalk, and bauxite. Contemporary manufacturing of Portland cement is a significant source of carbon dioxide emissions, prompting research into reducing its content in concrete through alternative...
590
Types of Cement II01:22

Types of Cement II

382
Portland blast-furnace cement is made by blending Portland cement clinker with granulated blast-furnace slag, which accounts for 25 to 65 percent of the cement's weight. Despite its similarities to ordinary Portland (Type I) cement in terms of fineness and setting times, its early strength is lower, though it achieves comparable strength later on. It's particularly suited for mass concrete structures and marine environments due to its lower heat of hydration and superior sulfate...
382
Manufacture of Concrete Masonry Units01:27

Manufacture of Concrete Masonry Units

368
The process of manufacturing concrete masonry units begins by mixing stiff concrete composed of Portland cement, aggregates, and water. This mixture is then poured into metal molds. To ensure the concrete settles uniformly and to avoid separation of its components, the mixture in the molds is subjected to vibration. Shortly after, the still-wet blocks are removed from the molds and placed on racks.
These wet blocks are then transported for curing, which can occur in one of two environments: a...
368
Porosity in Cement Paste01:18

Porosity in Cement Paste

428
The porosity of concrete is a measure of the void spaces within its structure. These spaces impact its strength and durability significantly. When water and cement interact, a chemical reaction called hydration creates a semi-solid paste. This paste includes combined water, making up approximately 23% of the cement's dry mass, and gel water, which fills minuscule voids known as gel pores, accounting for about 28% of the cement gel volume.
The balance of water to cement in the mix is...
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Ceramic Foam Granulate from Crashed Clinker Pavers.

Alexander Karamanov1, Ilian Djobov1, Feyzim Hodjaoglu1

  • 1Institute of Physical Chemistry, Bulgarian Academy of Sciences, "Acad. Georgi Bonchev" str. bld.11, 1113 Sofia, Bulgaria.

Materials (Basel, Switzerland)
|January 10, 2026
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Summary

Recycling ceramic clinker waste into high-quality foam granulate is feasible. This process yields impermeable, lightweight aggregates suitable for fire-resistant applications.

Keywords:
ceramic foamclinkerfoaming mechanismreusing

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Area of Science:

  • Materials Science
  • Ceramic Engineering
  • Waste Valorization

Background:

  • Ceramic clinker waste presents disposal challenges.
  • Developing sustainable uses for industrial byproducts is crucial.

Purpose of the Study:

  • To investigate the transformation of ceramic clinker debris into high-quality foam granulate.
  • To characterize the foaming mechanism and the properties of the resulting granules.

Main Methods:

  • Foaming process studied at elevated temperatures (150-200 °C higher than production).
  • Techniques used: Hot Stage Microscopy (HSM), Differential Thermal Analysis-Thermogravimetric Analysis coupled with Mass Spectrometry (DTA-TG-MS), X-ray Diffraction (XRD), and Scanning Electron Microscopy (SEM).

Main Results:

  • Foaming mechanism linked to oxygen release from Fe3+ to Fe2+ reduction after hematite melting and pseudobrookite dissolution.
  • Granules produced at 1280 °C for 30 min are impermeable to water.
  • Achieved properties: density (0.4-0.7 g/cm³), porosity (70-85 vol%), and compressive strength (0.7-1.1 MPa).

Conclusions:

  • The transformation of ceramic clinker waste into foam granulate is a viable process.
  • The resulting foam granulate meets criteria for high-quality, fire-resistant lightweight aggregates.