Nguyễn et al. (2023) — Optimization of Fly Ash-Based Polyethylene Fiber-Reinforced Engineered Cement-Free Composites with Low-Density and Ultra-Ductility Using Taguchi Robust Design Method
Citation
Nguyễn, P. H., Nguyễn, H. H., Lương, Q.-H., Bolander, J. E., & Lee, B. Y. (2023). Optimization of fly ash-based polyethylene fiber-reinforced engineered cement-free composites with low-density and ultra-ductility using Taguchi robust design method. Journal of Building Engineering, 66, 105946.
- DOI:
10.1016/j.jobe.2023.105946 - Atlas layer: core
- Related Victor Li book chapter: Chapter 4: Pseudo Strain-Hardening Criteria & Chapter 7: Alternative Reinforcing Fibers (PE Fibers) & Chapter 8: Multi-Objective Mix Optimization & Chapter 9: Green ECC (Fly Ash Geopolymers, pp. 307–342)
- Source PDF:
nguyn-2023-optimization-of-fly-ash-based-polyethylene.pdf - Extracted text:
full_text/nguyn-2023-optimization-of-fly-ash-based-polyethylene_full_text.md - Source note:
source_notes/nguyn-2023-optimization-of-fly-ash-based-polyethylene_source_note.md
Why this paper matters
A collaborative study between Chonnam National University and UC Davis applying the Taguchi Robust Design ($L_{16}$) method and Material Sustainability Indicators (MSI) to optimize curing temperature, duration, and PE fiber volume in fly ash geopolymer composites, yielding an optimal lightweight mixture ($\rho = 1.60\text{ g/cm}^3$, $f_c = 25.9\text{ MPa}$, $\sigma_u = 8.3\text{ MPa}$, $\epsilon_u = 11.0\%$) with 62 % lower carbon footprint than standard ECC.
Main contribution
- Implements a Taguchi $L_{16}(4^3)$ orthogonal design evaluating curing temperature (23 °C to 80 °C), curing duration (1 to 7 days), and PE fiber dosage (1.0 to 2.5 vol. %) on fly ash engineered cement-free composites (F-ECFC / EGC).
- Conducts ANOVA analysis, establishing that curing temperature is the single most dominant factor controlling geopolymer matrix dissolution, density, and composite tensile performance.
- Identifies unique mechanical regimes where composite direct tensile strength equals or exceeds compressive strength ($\sigma_u \ge f_c$).
- Derives multiple linear regression equations to optimize multi-objective criteria, verifying an optimal composite achieving $\rho = 1.60\text{ g/cm}^3$, $f_c = 25.9\text{ MPa}$, $\sigma_u = 8.3\text{ MPa}$, and $\epsilon_u = \mathbf{11.00\%}$.
- Performs Material Sustainability Indicators (MSI) life cycle modeling, demonstrating a 62 % carbon reduction and 48 % energy saving compared to conventional M45 ECC.
Evidence summary
- Material Matrix: 100 % Class F Fly Ash activated with Sodium Metasilicate Pentahydrate (SMP) and $\text{NaOH}$ (SH), $w/b = 0.345$.
- Fiber Specifications: UHMWPE fibers ($l_f = 12\text{ mm}, d_f = 24\ \mu\text{m}, \sigma_f = 3000\text{ MPa}, E_f = 100\text{ GPa}$) at $V_f = 1.0\%, 1.5\%, 2.0\%, 2.5\%$.
- Taguchi ANOVA & Statistical Findings:
- Curing temperature contributed 65.4 % to compressive strength variance and 51.2 % to tensile strain capacity variance.
- Optimal thermal window: 60 °C curing provides complete aluminosilicate polycondensation without matrix embrittlement.
- Optimized Composite Mechanical Validation:
- Density: $\rho = 1.60\text{ g/cm}^3$ (structural lightweight).
- Compressive strength: $f_c = 25.9\text{ MPa}$.
- Ultimate tensile strength: $\sigma_u = \mathbf{8.3\text{ MPa}}$.
- Direct tensile strain capacity: $\epsilon_u = \mathbf{11.00\%}$.
- Life Cycle Sustainability:
- Embodied carbon: $248\text{ kg CO}_2\text{-eq/m}^3$ (vs. $650\text{ kg CO}_2\text{-eq/m}^3$ for M45 ECC, -62 %).
- Embodied energy: $3.8\text{ GJ/m}^3$ (vs. $7.3\text{ GJ/m}^3$ for M45 ECC, -48 %).
Linked Atlas nodes
02_concepts/strain_hardening_criteria.md04_material_systems/geopolymer_ecc.md04_material_systems/green_ecc.md04_material_systems/lightweight_ecc.md04_material_systems/pe_ecc.md05_experiments/direct_tensile_test.md02_concepts/life_cycle_analysis.md
Relationship to Victor Li book
- Extends Victor Li (2019) Chapter 4 (PSH Criteria), Chapter 7 (PE Fibers), and Chapter 8 (Multi-Objective Optimization & Life Cycle Assessment).
- Integrates Taguchi statistical design with Victor Li's sustainability framework (Chapter 8), providing a quantitative method to balance environmental impact indicators against structural ductility and strength.
Claim-evidence rows to add
| Atlas node | Claim | Evidence summary | Page/Figure/Table | Status |
|---|---|---|---|---|
04_material_systems/pe_ecc.md |
Taguchi-optimized fly ash PE-EGC achieves 11.0 % tensile strain capacity and 8.3 MPa tensile strength at $\rho = 1.60\text{ g/cm}^3$ | Taguchi $L_{16}$ experimental matrix and JSCE direct tensile testing | Section 3.1–3.3, Fig. 5-8, Table 4 | verified_from_pdf |
02_concepts/life_cycle_analysis.md |
Fly ash PE-EGC reduces embodied carbon by 62 % ($248\text{ kg CO}_2/\text{m}^3$) and energy by 48 % compared to M45 ECC | Material Sustainability Indicators (MSI) and cradle-to-gate LCA modeling | Section 4.2, Fig. 10 & 11, Table 6 | verified_from_pdf |
Verification status
- PDF preserved: yes (
nguyn-2023-optimization-of-fly-ash-based-polyethylene.pdf) - Text extracted: yes (
full_text/nguyn-2023-optimization-of-fly-ash-based-polyethylene_full_text.md) - DOI verified: yes (
10.1016/j.jobe.2023.105946) - Metadata verified: yes (J. Build. Eng., Vol. 66, 105946, 2023)
- Claim-evidence matrix ready: yes
Cautions
- High curing temperatures ($> 80\ ^\circ\text{C}$) cause moisture loss and increase matrix fracture toughness, reducing composite tensile ductility.
- Curing regimens must be tightly controlled during precast manufacturing to achieve the predicted strength and ductility targets.