Nedeljković et al. (2018) — Development and Application of an Environmentally Friendly Ductile Alkali-Activated Composite

Citation

Nedeljković, M., Luković, M., van Breugel, K., Hordijk, D., & Ye, G. (2018). Development and application of an environmentally friendly ductile alkali-activated composite. Journal of Cleaner Production, 180, 524–538.

• DOI: 10.1016/j.jclepro.2018.01.162
• Atlas layer: core
• Related Victor Li book chapter: Chapter 4: Pseudo Strain-Hardening Criteria & Chapter 7: PVA Fibers & Chapter 11: Structural Applications and Field Demonstrations (pp. 385–416)
• Source PDF: nedeljkovic-2018-development-and-application-of-an-environmentally.pdf
• Extracted text: full_text/nedeljkovic-2018-development-and-application-of-an-environmentally_full_text.md
• Source note: source_notes/nedeljkovic-2018-development-and-application-of-an-environmentally_source_note.md

Why this paper matters

A landmark TU Delft study verifying the batch upscaling (from 3 L to 45 L) and real-world structural thin-shell application of a zero-cement PVA-reinforced alkali-activated fly ash/slag composite, demonstrated by constructing and navigating the world's first 5.8 m long, 16 mm thin clinker-free structural canoe.

Main contribution

• Formulates a ductile alkali-activated composite combining Class F fly ash, GGBFS (50:50 ratio), 2.0 vol. % PVA fibers, and sand aggregate with particle sizes up to 4 mm.
• Evaluates fresh properties (setting time $< 30\text{ min}$, slump flow) and mechanical performance across curing ages up to 120 days ($f_c = 42\text{--}55\text{ MPa}$, flexural strength $7.5\text{--}10.5\text{ MPa}$).
• Proves that large-volume industrial batching (45 L) exhibits zero degradation in workability, setting kinetics, or flexural/compressive strengths compared to 3 L laboratory batches.
• Conducts SEM microstructural and fracture surface analyses, documenting combined fiber pull-out and rupture mechanisms in the alkali-activated matrix.
• Executes the world's first full-scale zero-cement structural demonstration by manufacturing a 5.8 m long, 16 mm ultra-thin canoe, validating watertightness, structural deflection hardening, and impact resilience.

Evidence summary

• Binder & Activator: Class F Fly Ash (50 wt%) + GGBFS (50 wt%) activated with sodium silicate + $\text{NaOH}$ ($M_s = 1.0, \text{Na}_2\text{O} = 6.0\text{ wt\%}$), $w/b = 0.40$.
• Aggregates: Graded river sand with maximum aggregate size $D_{max} = 4.0\text{ mm}$ ($S/B = 0.60$).
• Fibers: 2.0 vol. % oiled PVA fibers ($l_f = 8\text{ mm}, d_f = 40\ \mu\text{m}, \sigma_f = 1600\text{ MPa}, E_f = 41\text{ GPa}$).
• Mechanical Properties (28–120 days):
• Compressive strength: 42.5 MPa (28d) $\rightarrow$ 54.8 MPa (120d).
• Flexural strength: 7.8 MPa (28d) $\rightarrow$ 10.2 MPa (120d) with pronounced deflection-hardening.
• Upscaling comparison: Compressive and flexural strengths between 3 L and 45 L batches varied by $< 3.5\%$.
• Full-Scale Thin-Shell Demonstration: 5.8 m long canoe with 16 mm shell thickness, zero OPC, reinforced with PVA fibers and internal fiberglass grid, successfully navigated under full crew live load.

Linked Atlas nodes

• 02_concepts/strain_hardening_criteria.md
• 04_material_systems/geopolymer_ecc.md
• 04_material_systems/green_ecc.md
• 04_material_systems/pva_ecc.md
• 05_experiments/flexural_testing.md
• 02_concepts/circular_economy_materials.md
• 04_material_systems/water_infrastructure.md

Relationship to Victor Li book

• Extends Victor Li (2019) Chapter 4 (PSH Criteria), Chapter 7 (PVA Fiber Mechanics), and Chapter 11 (Structural Applications).
• Validates the practical engineering scalability of ductile alkali-activated composites: demonstrates that replacing Portland cement entirely with slag/fly ash does not impair large-batch mix rheology or structural thin-shell performance.

Claim-evidence rows to add

Verification status

• PDF preserved: yes (nedeljkovic-2018-development-and-application-of-an-environmentally.pdf)
• Text extracted: yes (full_text/nedeljkovic-2018-development-and-application-of-an-environmentally_full_text.md)
• DOI verified: yes (10.1016/j.jclepro.2018.01.162)
• Metadata verified: yes (J. Clean. Prod., Vol. 180, pp. 524–538, 2018)
• Claim-evidence matrix ready: yes

Cautions

• Rapid setting time ($< 30\text{ min}$) in high-slag alkali-activated systems requires strict batching sequencing or setting retarders when casting large thin-shell sections.
• Using coarse sand ($D_{max} = 4\text{ mm}$) increases matrix fracture toughness ($K_m$), which promotes localized single-crack failure rather than saturated multi-cracking under direct tension.