Open-access Pioneering the next frontier in construction with high-strength concrete infused by nano materials

ABSTRACT

The advancement of nano engineering technology plays a major role in the cementitious materials especially graphene oxide which got high attention. In this research the addition of graphene oxide, silica fume and flyash with various mix proposition in partial replacement of cement have be investigated for mechanical properties of concrete which is the macro level (workability, strength behavior, flexural behavior, water absorption, porosity, and durability) and micro level structural analysis (SEM analysis). Polycarboxylate ethers are used as super plasticizers to offset this decrease, which substantially improves the concrete’s workability. Silica fume and fly ash are utilized in fixed proposition of 10% of silica fume and 10% of fly ash, by weight, to enhance the strength of concrete. After conducting various tests, it has been determined that the optimal combination involves a 10% replacement of both silica fume and fly ash for ordinary Portland cement, particularly grade 53, resulting in superior outcomes. Addition to its varying percentages from 0, 0.01, 0.02, 0.03, 0.04 and 0.05% of Graphene oxide used to find the optimum percentage of GO by weight of ordinary Portland cement to obtain high strength. The optimum percentage of grapheme oxide to be replaced with cement is 0.04%.

Keywords: Graphene oxide; Silica fume; Flyash; Durability; Micro analysis

1. INTRODUCTION

Nanotechnology unlocks numerous applications by leveraging the exceptional chemical and physical properties of nanomaterials, transforming the construction sector. This approach is characterized by enhanced durability, early high compressive strength, superior splitting tensile strength, and a high elastic modulus, making it invaluable in advancing concrete technology [1]. Among these innovations, graphene oxide (GO) stands out for its ability to bond and disperse effectively within the cementitious matrix. This interaction significantly refines the microstructure of concrete, providing essential insights for those seeking to enrich its practical properties using GO [2]. Research has demonstrated that incorporating various nanomaterials into concrete and mortar substantially improves mechanical attributes, such as compressive strength, modulus of rupture, and overall durability. These enhancements are critical for applications requiring robust and long-lasting structures [3]. Nano-core, a vital element in modern construction design and production, plays a vital role in regulating deflection and mitigating the effects of chloride penetration, which is a common cause of concrete deterioration. Notably, nano silica’s “core effect” is instrumental in optimizing these properties, ensuring improved performance and longevity [4].

Nanoparticles play a pivotal role in advancing cement technology by enhancing its mechanical strength, durability, and self-healing properties. This study explores the innovative applications of nanotechnology, highlighting its transformative potential in cement and concrete development. As outlined in [5], the integration of nanomaterials offers significant opportunities to improve performance while reducing environmental impacts. The inclusion of supplementary materials such as fly ash, slag, and steel fibers (SF) has been extensively studied, demonstrating their effectiveness in boosting the mechanical and durability characteristics of concrete while lowering its ecological footprint [6]. Moreover, incorporating both nano-sized and micro-sized silica particles into Ordinary Portland Cement (OPC) pastes has shown promising results, particularly in improving hydration kinetics and refining microstructural properties. By focusing on these advancements, this work emphasizes the potential of nanotechnology to revolutionize cement and concrete, addressing modern construction challenges and promoting sustainability [7].

Incorporating alternative cementing components, such as fly ash, in place of a portion of traditional cement helps reduce greenhouse gas emissions, contributing to more environmentally friendly concrete production. This method not only lowers energy consumption but also preserves natural resources, making concrete more sustainable and “green” [8]. The pozzolanic properties of fly ash, as well as its ability to function as a filler, significantly enhance cement performance. This is demonstrated in the study The Impact of Fly Ash Particle Size on the Physical Properties of Concrete, which validates fly ash’s role in improving concrete’s properties [9]. The research revealed that replacing up to 40% of the cement with fly ash effectively reduced chloride permeability at all stages, suggesting that this may be the optimal replacement level for improving durability. Additionally, the study found that each cement replacement material, including fly ash, tended to increase compressive strength while decreasing water permeability, further enhancing the concrete’s overall performance and longevity [10].

The specimens’ flexural strength increased when cement was substituted with up to 15% SF. These results highlight the potential benefits, especially within the designated replacement range, of SF integration as a cementitious element in concrete mixes [11]. Various SF replacement in a increment of 5% upto 25% were tested on cube samples during periods of 3, 7, 14, and 28 days. In this investigation, a 1:2:4 mix by weight was employed as the mix proportioning. The findings showed that the strength of cement enriched up to a 10% SF replacement level. Compressive strength was found to decrease for all testing ages, i.e., three, seven, fourteen and twenty eight days, when the replacement level rose above 10% to 15% and above [12]. The acceleration of the hardening process in the presence of NS. This observation indicates that Nano Silica has the capacity to play a vital role in enriching the early-age performance of cement-based materials, making it an attractive candidate for applications where rapid strength development is essential [13]. In place of cement, NS is used in the proportions of 1, 3, 5, and 10%, while silica fume is utilised in the amounts of 5, 10, and 15%. They have researched compressive strengths, hydration heat, setting times, consistency, and setting times. The outcomes demonstrated that the 5% NS is efficient in the necessary parameters [14]. The cement paste is blended with nano-silica, evaluated the hydration process in the cement paste. They applied the SEM and FTIR methods to the samples in order to examine the hydration process at various stages [15].

A significant concern related to the use of graphene oxide (GO) in cement-based materials. Their observations revolve around the potential challenges that may arise when introducing GO into cement paste and concrete [16]. They particularly emphasize that the substantial specific surface area of GO can lead to an increase in viscosity, potentially hindering the workability and fluidity of the cement mixture. This issue has the potential to impose limitations on the practical incorporation of GO in concrete technology [17]. These results demonstrate graphene oxide’s (GO) enormous potential as a reinforcing ingredient in cement-based composites. The enhancement of these materials’ physical qualities by GO is indicated by the improvements in flexural and compressive strengths [18]. The use of GO can help build stronger and more resilient cementitious materials, which will eventually improve the performance and lifespan of structures in the built environment. This has encouraging implications for a variety of structural applications and construction [19]. GO addition simply encourages the development of hydration products and does not alter the kinds of hydration crystals. The hydration crystals create a tight microstructure by intimately entwining with one another. Based on these elements, GO-cement composites have greater compressive strength compared to plain samples [20].

2. MATERIAL

2.1. Cement

The selection of the ideal cement grade and quality is paramount, particularly when aiming to achieve HSC. Cement, as the primary binding agent in the concrete matrix, is of paramount importance [21]. In our research, we have employed OPC 53 grade for the concrete casting process. The cement exhibited notable characteristics, featuring a specific gravity of 3.15 and a specific surface area of 315 m2/kg. Fineness, a vital parameter, was determined at 2.9%, ensuring optimal particle distribution. Consistency, gauged at 28.4%, demonstrated a favorable workability range. The cement displayed a deliberate setting time, with an initial setting time of 145 minutes and a final setting time of 285 minutes. Impressively, the 28-day strength test revealed robust performance at 60.60 N/mm2, attesting to the high-strength potential. The soundness test exhibited minimal expansion at 1 mm, signifying the cement’s durability and stability in construction applications.

2.2. Flyash

The chemical composition of fly ash highlights its versatility and potential as a supplementary construction material. Silicon dioxide (SiO 2), accounting for 53.90%, plays a vital role in enhancing structural integrity, while aluminum oxide (Al2O3) at 21.30% contributes significantly to thermal resistance. Calcium oxide (CaO), present at 0.89%, influences pozzolanic activity, enhancing cementitious properties. Ferric oxide (Fe2O3), comprising 17.10%, imparts strength and coloration to the material. Magnesium oxide (MgO) at 3.52% provides chemical stability, ensuring resilience against environmental conditions. Sulphur trioxide (SO3), at 1.40%, is vital for setting time and overall durability, ensuring consistent performance. The Loss on Ignition (LOI), recorded at 0.49%, reflects low volatile content, which is essential for maintaining quality and minimizing emissions. This well-balanced composition underscores the utility of fly ash in construction applications, offering enhanced mechanical strength, improved thermal and chemical stability, and reduced environmental impact.

2.3. Silica fume

The test results of the examined material confirm its exceptional quality and strict compliance with established standards. The specific surface area, measured at 202 m2/g, slightly exceeds the typical range of 200 ± 20 m2/g, indicating a fine texture suitable for its intended applications. At 20 °C, the specific gravity registers at 2.28, comfortably within the acceptable range of 2.00 to 2.40 [22, 23]. The material’s pH, recorded at 4.15, is well within the standard range of 3.7 to 4.5, ensuring chemical stability. Additionally, the sieve residue is minimal at 0.02%, reflecting its uniform particle size distribution. Notably, the concentration of SiO2 stands at an impressive 99.88%, far surpassing expectations, while the levels of carbon, chloride, and impurities such as Al2O3, TiO2, and Fe2O3 remain well below specified limits. These results collectively affirm the material’s superior quality, fulfilling or exceeding required standards across multiple parameters, making it highly suitable for advanced applications.

2.4. Graphene oxide

This material, characterized by an impressive 99% purity, is presented as an ultrathin layer measuring 0.8 to 2 nm in thickness. Its average lateral dimensions range from 5 to 10 µm, with a distinctive 1 to 3 layers structure. The composition includes 60–80% carbon, 15–32% oxygen, 1–2% hydrogen, and 1–2% nitrogen, highlighting its rich elemental makeup. The black-colored substance possesses a vast surface area of 110–2508 m2/g, enhancing its functional versatility, and maintains a low bulk density of 0.5 g/cm3, making it extremely lightweight [24]. This odorless material, with a chemical formula of C, appears as a fluff-like, very light powder. It has minimal sulfur content, below 1%, and a specific gravity of 2.267, reinforcing its stable chemical nature. Such a unique combination of properties underscores its potential for diverse applications, ranging from nanotechnology and catalysis to energy storage and environmental remediation.

2.5. Fine aggregate

Sand, a crucial component in construction, is typically found in varying zones with differing degrees of fineness, comprising either rounded or angular grains. The Indian Standard IS 383–1970 outlines the specifications for aggregates, including detailed descriptions of the four recognized zones for sand gradation [25]. Fine aggregate used in concrete often includes manufactured sand (M-sand), a processed material created to meet specific quality standards. M-sand in this context has a relative density of 2.65, a fineness modulus of 2.80, and a water absorption rate of 1%. These parameters ensure the sand’s suitability for concrete casting, contributing to the desired workability and strength. Its controlled grading and physical properties provide consistent performance in construction applications, minimizing variability often associated with natural sand. The precise characteristics of M-sand make it an effective and sustainable alternative in modern concrete production, aligning with industry demands for high-quality materials.

2.6. Coarse aggregate

Aggregate used in construction must conform to the specifications outlined in IS 383–1970 to ensure quality and performance. According to these guidelines, the nominal size of coarse aggregate should be as large as practicable, but it must not exceed 20 mm or the minimum thickness of the structural member, whichever is smaller [26]. For most construction applications, a blend of 20 mm and 12 mm coarse aggregates in a ratio of 60% and 40%, respectively, is commonly used. This combination provides an optimal balance between workability and strength. The selected aggregates for casting have a relative density of 2.74, ensuring sufficient bulk density for stability, a fineness modulus of 7.71 for proper grading, and a water absorption rate of 0.5%, which ensures minimal water uptake and maintains the mix’s consistency. These characteristics collectively contribute to the durability and mechanical performance of the concrete, making the aggregates ideal for structural applications.

2.7. Super plasticer

To enhance workability, a polycarboxylate ether-based superplasticizer is incorporated at a dosage of 3 kg per cubic meter of concrete. This admixture, with a relative density of 1.08, significantly improves the flow characteristics of the concrete mix without compromising its structural integrity [27, 28]. One of the key benefits of using this superplasticizer is its ability to reduce the water requirement by approximately 30%. This reduction not only optimizes the water-cement ratio but also results in improved concrete strength and durability. By minimizing water content, the superplasticizer contributes to denser packing of cement particles, enhancing hydration efficiency and leading to superior mechanical properties. This admixture is particularly effective in producing high-performance concrete, where maintaining workability at low water content is critical. Its use aligns with modern construction demands for sustainable and durable materials, ensuring long-term structural performance under varied environmental conditions.

3. MIX PROPOSITIONS

Mix design is an intricate process, critical in engineering concrete to meet specific performance criteria such as workability, strength, and durability, all while ensuring cost-effectiveness. In our approach, we adhere to the mix design procedure outlined by IS 10262 – 2019, a recognized standard in the field. This meticulous process enables us to tailor the concrete composition to our precise requirements. For our project, we have honed in on achieving M60 grade concrete, signifying a formidable level of compressive strength. To strike the ideal balance between these essential properties, we have meticulously set the water-cement ratio at 0.29. This careful selection of parameters aligns with our pursuit of creating concrete that not only meets but exceeds performance expectations while ensuring economical feasibility. Figure 1 shows the methodology flow.

Figure 1
Methodology.

4. RESULTS AND DISCUSSION

4.1. Compressive strength test

The addition of Graphene Oxide (GO) in various proportions significantly enhances the compressive strength of concrete [29, 30]. In a series of mixes (M1 to M6), the conventional mix (M1) served as a baseline, with subsequent mixes incorporating 0.01% to 0.05% GO. The results at 7, 14, and 28 days consistently reveal improved performance with escalating GO content. Mix M5, containing 0.04% GO, emerged as the standout performer, exhibiting the highest compressive strength values at all tested durations. This underscores the potential of graphene oxide as a reinforcing agent, offering promising prospects for the development of high-strength and durable concrete formulations. The graphical display of the compressive strength test results is shown in Figure 2.

Figure 2
Comparison of compressive strength of various mixes.

4.2. Split tensile strength

The introduction of Graphene Oxide (GO) in varying concentrations has a discernible impact on the split tensile strength of concrete, as evidenced by mixes M1 to M6. The conventional mix (M1) served as a baseline, with subsequent mixes featuring incremental GO content from 0.01% to 0.05% [31]. Results at 7, 14, and 28 days consistently showcase enhanced split tensile strength, indicating the reinforcing effect of graphene oxide. Mix M5, comprising 0.04% GO, emerges as the top performer across all tested durations, underscoring GO’s potential to augment the material’s tensile properties. This highlights the promising role of graphene oxide in fortifying concrete and optimizing its structural characteristics. The graphical display of the split tensile strength test results is presented in Figure 3.

Figure 3
Comparison of split tensile strength.

4.3. Flexural strength test

The incorporation of Graphene Oxide (GO) in concrete mixtures (M1 to M6) reveals a notable enhancement in flexural strength at 28 days. The conventional mix (M1) served as a baseline, registering a flexural strength of 6.65 MPa. As the concentration of GO increased from 0.01% to 0.05%, a consistent improvement in flexural strength was observed. Mix M5, featuring 0.04% GO, exhibited the highest flexural strength at 8.15 MPa, showcasing the reinforcing effect of graphene oxide. These results underscore the potential of GO as a valuable additive in optimizing the flexural performance of concrete, contributing to its overall structural resilience. The graphics depicting the results of the flexural strength test are displayed in Figure 4.

Figure 4
Comparison of flexural strength.

4.4. Permeability

The introduction of Graphene Oxide (GO) into concrete mixtures (M1 to M6) has demonstrated a substantial influence on permeability, particularly evident over 28, 56, and 90 days. The conventional mix (M1) displayed a permeability of 0.043 × 10^(–6) mm/sec at 28 days, gradually improving to 0.03 × 10^(–6) mm/sec at 90 days. With incremental additions of GO ranging from 0.01% to 0.05%, a consistent reduction in permeability was observed. Notably, Mix M6, containing 0.05% GO, exhibited the lowest permeability values at all tested durations, indicating the potential of graphene oxide in mitigating the permeability of concrete and enhancing its durability over time. The findings of the permeability test are represented graphically in Figure 5.

Figure 5
Comparision of permeability.

4.5. Sorptivity

Incorporating Graphene Oxide (GO) into concrete mixtures (M1 to M6) has proven effective in reducing sorptivity, a key indicator of water absorption. The conventional mix (M1) exhibited a sorptivity of 0.02 mm/s^(1/2) at 28 days, gradually decreasing to 0.013 mm/s^(1/2) at 90 days. With incremental additions of GO ranging from 0.01% to 0.05%, a consistent downward trend in sorptivity was evident. Remarkably, Mixes M5 and M6, containing 0.04% and 0.05% GO, respectively, displayed the lowest sorptivity values at all tested durations, highlighting the efficacy of graphene oxide in mitigating water absorption and reinforcing the concrete’s resistance to environmental factors over time. The graphical display of the sorptivity test findings is presented in Figure 6.

Figure 6
Comparision of sorptivity.

4.6. SEM analysis

Figure 7, Figure 8, Figure 9, Figure 10, Figure 11, Figure 12 represents the SEM image of conventional and nano modified concrete mix. The diffraction patterns indicate the presence of key compounds such as CH, CSH, ettringite, and other chemicals. Notably, CH and CSH are observed at different phase angles. The amorphous nature of CSH results in low-intensity peaks in the diffraction pattern. Silicon dioxide (SiO2) in the form of quartz and silica plays a vital role. Quartz, characterized by its hexagonal crystalline structure, is the predominant source and exhibits higher intensity peaks. The presence of alite and belite is indicative of the absence of unhydrated products in the nona modified concrete mix. The SEM analysis of the M5 sample reveals a denser matrix and a higher concentration of CSH gel, CH, and ettringite. This suggests increased hydration and higher levels of hydrated products compared to CC. The presence of needle-like ettringite and hexagonal CH particles filling interstitial spaces enhances the material’s durability. Microscopic images also reveal asymmetric crystal particles and the growth of flaky crystals produced by the hydration process, indicative of C-S-H presence. The densely packed cement matrix and the aggregate transition area signify robust bonding.

Figure 7
SEM image of M1 mix.
Figure 8
SEM image of M2 mix.
Figure 9
SEM image of M3 mix.
Figure 10
SEM image of M4 mix.
Figure 11
SEM image of M5 mix.
Figure 12
SEM image of M6 mix.

4.7. XRD

Determining the qualitative analysis of minerals is the aim of this test. The glass and crystallization components have been quantitatively identified using this method. Cu K radiation at 0.1514 nm, 30 kV of voltage, and 10 mA of current were used to construct the curves. The particle diffraction covered the 10° to 80° range with a scan step size of 0.02°/s. Samples were collected for 30 minutes. The hydration products are identified via XRD analysis. Different concrete mixtures produce radically different XRD patterns. The XRD graph revealed the crystalline hydration products portlandite (P), alite (A), and belite (B), which are calcium hydroxide. The crystal phase is revealed by the peak intensity. The high peak intensities for sample’s M1 to M6 are at 22.09°, 26.66°, 29.45°, 32.21°, 34.31° and 31.05°. The creation of alite and belite is represented by the greatest peak intensities at M5 mix, whereas portlandite is represented by the lowest peak intensities. Alite and belite have an increase in peak intensity as hydration progresses, but portlandite has a drop in peak intensity. This demonstrates that the micropores were completely filled, lowering the porosity. Figures 13, Figures 14, Figures 15, Figures 16, Figures 17, Figures 18 shows the X-ray diffraction for conventional mix and the nano modified concrete mixes. The test results shows the CSH value increases with enrich in the GO content this reducing the copes and increasing the cementious materials in the mix. Thus the strength and durability of the M5 mix is more superior compared to all other mix.

Figure 13
XRD image of M1 mix.
Figure 14
XRD image of M2 mix.
Figure 15
XRD image of M3 mix.
Figure 16
XRD image of M4 mix.
Figure 17
XRD image of M5 mix.
Figure 18
XRD image of M6 mix.

5. CONCLUSION

In this research the percentage of flyash, silica fume is kept constant as 10% each as a replacement for cement and various percentage of GO is added from 0 to 0.05% and studied the mechanical properties and durability properties of concrete.

  • The compressive strength of the concrete increased significantly by 44% with the addition of graphene oxide compared to conventional concrete, indicating enhanced durability.

  • The split tensile strength also improved by 28% when graphene oxide was added, compared to regular concrete, demonstrating increased resistance to tensile forces.

  • The modulus of rupture increased by 22% when Graphene oxide is added compared to conventional concrete.

  • By adding graphene oxide the durability characteristics of concrete has been improved indicating a durable high strength concrete.

  • The SEM photograph conforms that the concrete containing graphene oxide has very low voids and more CSH gel indicating high compressive strength of concrete compared to conventional concrete.

  • The high peak intensities for sample’s M1 to M6 are at 22.09°, 26.66°, 29.45°, 32.21°, 34.31° and 31.05°. The creation of alite and belite is represented by the greatest peak intensities at M5 mix, whereas portlandite is represented by the lowest peak intensities.

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Publication Dates

  • Publication in this collection
    27 Jan 2025
  • Date of issue
    2025

History

  • Received
    23 Oct 2024
  • Accepted
    02 Dec 2024
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