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At least 55 records · Page 3

All sources NASA NTRS DOE OSTI

NASA NTRS2008

Evaluation of Sulfur 'Concrete' for Use as a Construction Material on the Lunar Surface

Combining molten sulfur with any number of aggregate materials forms, when solid, a mixture having attributes similar, if not better, to conventional water-based concrete. As a result the use of sulfur "concrete" on Earth is well established, particularly in corrosive environments. Consequently, discovery of troilite (FeS) on the lunar surface prompted numerous scenarios about its reduction to elemental sulfur for use, in combination with lunar regolith, as a potential construction material; not requiring water, a precious resource, for its manufacture is an obvious advantage. However, little is known about the viability of sulfur concrete in an environment typified by extreme temperatures and essentially no atmosphere. The experimental work presented here evaluates the response of pure sulfur and sulfur concrete subjected to laboratory conditions that approach those expected on the lunar surface, the results suggesting a narrow window of application.

Grugel, R. N.↗

NASA NTRS2010

Field Testing of High Current Electrokinetic Nanoparticle Treatment for Corrosion Mitigation in Reinforced Concrete

Electrokinetic Nanoparticle (EN) treatment was used as a rapid repair measure to mitigate chloride induced corrosion of reinforced concrete in the field. EN treatment uses an electric field to transport positively charged nanoparticles to the reinforcement through the concrete capillary pores. Cylindrical reinforced concrete specimens were batched with 4.5 wt % salt content (based on cement mass). Three distinct electrokinetic treatments were conducted using high current density (up to 5 A/m2) to form a chloride penetration barrier that was established in 5 days, as opposed to the traditional 6-8 weeks, generally required for electrochemical chloride extraction (ECE). These treatments included basic EN treatment, EN with additional calcium treatment, and basic ECE treatment. Field exposures were conducted at the NASA Beachside Corrosion Test Site, Kennedy Space Center, Florida, USA. The specimens were subjected to sea water immersion at the test site as a posttreatment exposure. Following a 30-day post-treatment exposure period, the specimens were subjected to indirect tensile testing to evaluate treatment impact. The EN treated specimens exhibited 60% and 30% increases in tensile strength as compared to the untreated controls and ECE treated specimens respectively. The surfaces of the reinforcement bars of the control specimens were 67% covered by corrosion products. In contrast, the EN treated specimens exhibited corrosion coverage of only 4%. Scanning electron microscopy (SEM) revealed a dense concrete microstructure adjacent to the bars of the treated specimens as compared to the control and ECE specimens. Energy dispersive spectroscopic (EDS) analysis of the polished EN treated specimens showed a reduction in chloride content by a factor of 20 adjacent to the bars. This study demonstrated that EN treatment was successful in forming a chloride penetration barrier rapidly. This work also showed that the chloride barrier was effective when samples were exposed to field conditions at one of the most severely corrosive environments in North America.

Cardenas, Henry↗

NASA NTRS2005

Performance Assessment of Refractory Concrete Used on the Space Shuttle's Launch Pad

The John F. Kennedy Space Center (KSC) maintains several facilities for launching space vehicles. During recent launches it has been observed that the refractory concrete materials that protect the steel-framed flame duct are breaking away from this base structure and are being projected at high velocities. There is significant concern that these projected pieces can strike the launch complex or space vehicle during the launch, jeopardizing the safety of the mission. A qualification program is in place to evaluate the performance of different refractory concretes and data from these tests have been used to assess the performance of the refractory concretes. However, there is significant variation in the test results, possibly making the existing qualification test program unreliable. This paper will evaluate data from past qualification tests, identify potential key performance indicators for the launch complex, and will recommend a new qualification test program that can be used to better qualify refractory concrete.

Trejo, David↗

NASA NTRS2009

Properties of Refractory Concrete in Tension and Compression

Refractory concrete on the LC-39A Flame Deflector has been damaged during multiple Space Shuttle launches (e.g. STS-124, STS-126, STS-119, and STS-125, STS-127). These events have prompted a better understanding of the system via an analytical model of the Flame Deflector assembly to include the Fondu Fyre refractory concrete. This model requires test data inputs of the refractory concrete's mechanical properties, which include stress versus strain curves in tension and compression, modulus of elasticity, and Poisson's ratio. Sections of Fondu Fyre refractory concrete removed from the LC-39A Flame Deflector were provided for this testing.

Sampson, Jeffrey↗

NASA NTRS2008

Field Testing of High Current Electrokinetic Nanoparticle Treatment for Corrosion Mitigation in Reinforced Concrete

This work examines field performance of nanoscale pozzolan treatments delivered el ctrokinetically to suppress chloride induced corrosion of concrete reinforcement. The particles are 20 nm silica spheres coated with 2 nm alumina particles that carry a net positive charge. Earlier work demonstrated that the alumina particles were stripped from the silica carriers and formed a dense phase with an interparticle spacing that is small enough to inhibit the transport of solvated chlorides. A D.C. field was used to inject the particles into the pores of concrete specimens, directly toward the mild steel bars that were embedded within each 3 inch diameter by 6 inch length concrete specimen. The voltage was held constant at 25 v per inch of concrete cover for a period of 7 days. These voltages permitted current densities as high as 3 A/sq m. During the final 3 days, a 1 molar solution of calcium nitrate tetrahydrate was used to provide a source of calcium to facilitate stronger and more densified phase formation within the pores. In a departure from prior work the particle treatments were started concurrent with chloride extraction in order to determine if particle delivery would inhibit chloride transport. Following treatment the specimens were immersed in seawater for 4 weeks. After this posttreatment exposure, the specimens were tested for tensile strength and the steel reinforcement was examined for evidence of corrosion. Scanning electron microscopy was conducted to assess impact on microstructure.

Calle, Luz Marina↗

NASA NTRS2015

Electrokenitic Corrosion Treatment of Concrete

A method and apparatus for strengthening cementitious concrete by placing a nanoparticle carrier liquid in contact with a first surface of a concrete section and inducing a current across the concrete section at sufficient magnitude and for sufficient time that nanoparticles in the nanoparticle carrier liquid migrate through a significant depth of the concrete section.

Cardenas, Henry E↗

NASA NTRS2016

Electrokinetic Strength Enhancement of Concrete

Cardenas, Henry E.↗

NASA NTRSDate not supplied

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson↗

DOE OSTI2024

Strategies for Developing High-Volume Fly Ash Concrete with High Early-Age Strength for Precast Applications

Partial replacement of portland cement with supplementary cementitious materials (SCMs), such as fly ash, is an effective strategy for improving durability and reducing the CO 2 footprint of concrete. However, using high-volume fly ash (HVFA) binders in precast and prestressed concrete is currently limited; largely due to reduced early-age strength development that impedes rapid production and prestressing of precast concrete. To investigate and address this challenge, HVFA mortars with a minimum of 40% fly ash by mass of cementitious materials were developed and tested in this study. Two fresh fly ashes (an ASTM C618 Class F and a Class C) and a landfilled fly ash (Class F) were included. Various strategies for improving the early strength were evaluated, including gypsum optimization, chemical accelerators, steam curing, use of CSA cements, and adding other reactive SCMs like silica fume, calcined clay, and slag cement. Steam curing and the use of CSA cement at high dosages (40% of total binder) were found to be the most successful strategies across all three fly ashes. Additionally, significant improvements were observed with gypsum optimization (for Class C fly ash) and the use of accelerators (for Class F fly ashes), and these strategies are likely to be more feasible considering later-age strength and economic viability. Interestingly, HVFA mixtures made with the landfilled fly ash used in this study were able to achieve high early strengths with water-to-cementitious materials ratio adjustment alone. As a result, these HVFA mixtures were also found to be less responsive to accelerators when compared to the fresh Class F fly ash, highlighting an important distinction between the materials despite the similarity in chemical composition.

42 ENGINEERING↗

DOE OSTI2025

Multiphysics simulation of recent experiments on alkali‐silica reaction expansion in reinforced concrete members

Alkali‐silica reaction (ASR) is an important degradation process that causes volumetric expansion and damage in concrete, and is affected significantly by the local temperature, moisture and stress conditions that often vary across the regions of a structure. Numerical simulation is essential to predict the progression and effects of ASR on the performance of structures. Because of the interactions between thermal and moisture transport and mechanical deformation, it is important for numerical models to represent all these physical phenomena and the coupling between them. Simulations of ASR in reinforced concrete (RC) structures are further complicated by the need to capture interactions between concrete and embedded reinforcing bars. Here, this paper describes the implementation of a scalable, coupled‐physics ASR model for simulating RC structures and assesses the ability of that model to predict ASR‐induced expansion in recent laboratory tests on RC block and beam specimens. These laboratory tests and the simulation approach were selected because of their applicability to RC structural‐scale simulations. This validation study helps builds confidence the ability of this approach to model ASR expansion in large, complex RC structures, which is a current high‐priority need.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Cement and concrete as carbon sinks: Transforming a climate challenge into a carbon storage opportunity

Cement and concrete, while traditionally recognized as the main contributors to anthropogenic CO 2 emissions, also have untapped capacity to serve as substantial and scalable carbon sinks. This perspective examines how engineered mineral carbonation can transform cement-based materials into functional carbon storage systems, generating both environmental and economic value. We review the fundamental mechanisms of CO 2 uptake in cementitious systems, highlighting current limitations in reaction kinetics, phase control, and durability under varying environmental conditions. Emphasis is placed on the utilization of alkaline industrial residues and emerging magnesium-based cements, which offer synergistic pathways for carbon sequestration and circular resource use. We further assess the performance trade-offs associated with CO 2 uptake and the feasibility of deploying these technologies on industrial scales. A strategic roadmap is proposed that integrates scientific innovation, regulatory alignment, and carbon accounting in the life cycle to accelerate the adoption of carbon-storing concrete. This perspective provides a comprehensive framework to advance cement and concrete as engineered carbon sinks and supports the transition to a climate-positive construction industry.

Carbon storage↗

DOE OSTI2025

Effect of Fatigue on the Capacity and Performance of Structural Concrete

The goal of this project was to enhance the understanding of the fatigue behavior of concrete structures for the purpose of improving the design and assessment of towers and foundations that support wind turbines, which must endure repeated loadings from wind, waves, operations, and other dynamic effects that cause material degradation. This was achieved through physical experiments, a review of the technical literature, and collaboration with experts in key subject areas. The project produced a comprehensive database of publicly available fatigue data, several technical papers presenting the research findings, and two Technotes to be published by the American Concrete Institute that advance best practices in fatigue testing and enable the development of concrete-specific fatigue (S-N) (stress-life) curves. These contributions are expected to enhance the durability and cost-effectiveness of wind turbine support structures.

17 WIND ENERGY↗

DOE OSTI2024

Improving the Concrete Crack Detection Process via a Hybrid Visual Transformer Algorithm

Inspections of concrete bridges across the United States represent a significant commitment of resources, given their biannual mandate for many structures. With a notable number of aging bridges, there is an imperative need to enhance the efficiency of these inspections. This study harnessed the power of computer vision to streamline the inspection process. Our experiment examined the efficacy of a state-of-the-art Visual Transformer (ViT) model combined with distinct image enhancement detector algorithms. We benchmarked against a deep learning Convolutional Neural Network (CNN) model. These models were applied to over 20,000 high-quality images from the Concrete Images for Classification dataset. Traditional crack detection methods often fall short due to their heavy reliance on time and resources. This research pioneers bridge inspection by integrating ViT with diverse image enhancement detectors, significantly improving concrete crack detection accuracy. Notably, a custom-built CNN achieves over 99% accuracy with substantially lower training time than ViT, making it an efficient solution for enhancing safety and resource conservation in infrastructure management. These advancements enhance safety by enabling reliable detection and timely maintenance, but they also align with Industry 4.0 objectives, automating manual inspections, reducing costs, and advancing technological integration in public infrastructure management.

42 ENGINEERING↗

DOE OSTI2025

Graphene Oxide Nanoribbons for High Early-Strength Cement Concrete

Longitudinal oxidative unzipping of the outer walls of multiwalled carbon nanotubes (MWCNTs) yields graphene oxide nanoribbons (GONRs), which exhibit greater open surface area and functional edge content than MWCNTs. This paper presents a study of the nano-amendment of Portland cement concrete with GONRs in concentrations between 0.05% (in weight of cement, wt%) and 0.0005 wt%, thus up to two orders of magnitude lower than that reported as lower-bound in the archival literature. The dispersibility in aqueous solution as a function of GONR concentration and oxygen weight content (O%) was assessed through dynamic light scattering (DLS) and zeta potential analysis. The results indicated that less effective suspensions were obtained for 0.05 wt% of GONRs and 22.7 O%. Therefore, GONR water suspensions with 30-40% O% were used to manufacture 50 mm × 100 mm cylindrical concrete specimens. After 7 days of curing, results from uniaxial compression tests using four specimens per configuration (MWCNT concentration and O%) showed that the incorporation of GONRs resulted in an average increase in compressive strength up to 45%. Consistent with the DLS and compression test results, SEM micrographs showed well-dispersed GONRs together with accelerated and preferential formation of calcium silicate hydrates (C-S-H) for all GONR concentrations. The results indicate, for the first time, that the incorporation of very small concentrations (as low as 0.0005 wt%) of well-dispersed GONR amendments can significantly enhance the early-age concrete strength. However, such enhancement became insignificant after 28 days of curing.

cement↗

DOE OSTI2025

PyCMG-based Simulation of Volumetric Concrete Microstructure

Concrete is a complex, heterogeneous material with a microstructure composed of aggregates, cement paste, and pores spanning multiple length scales. Understanding this microstructure is critical for advancing the performance, durability, and modeling of concrete-based systems. While experimental imaging such as X-ray computed tomography (XCT) provides valuable insights, generating large datasets with detailed ground truth annotations is both costly and labor-intensive due to challenges in segmenting similar phases, such as aggregates and cement paste, that often share similar attenuation properties. To address this, we developed a pipeline to simulate realistic 3D concrete microstructures using the open-source Python package PyCMG. This simulation effort focuses on generating high-fidelity, annotated microstructures that can serve as training or benchmarking datasets for image analysis, segmentation algorithms, and machine learning models, particularly in scenarios where experimental data is scarce.

Ziabari, Amir [Oak Ridge National Laboratory; ORNL↗

DOE OSTI2025

Development of Calcined Clay/Calcium Sulfate Blends for Robust Performance of LC3 Concrete

This report documents the development of robust blends of calcined clays (CCs) with calcium sulfate (gypsum) for application in limestone calcined clay cement (LC3) systems. The U.S. cement industry faces supply chain constraints and high energy intensity, motivating the need for alternative supplementary cementitious materials. Calcined clays are abundant and highly reactive when properly processed, but their variable physical and chemical characteristics can negatively impact hydration balance, rheology, and admixture demand in LC3 concretes. To address this, five calcined clays, two Portland cements, ground limestone, gypsum, and a polycarboxylate dispersant were procured. Isothermal calorimetry and mini-cone flow tests were used to determine sulfate and dispersant demand. Results show that the addition of approximately 6.7% gypsum, relative to the calcined clay weight, consistently balanced sulfate consumption across the LC3 systems studied. Dispersant demand, however, varied significantly with clay source, demonstrating the need for tailored admixture strategies. These findings confirm that supplying CC–gypsum blends directly to concrete producers is a viable approach to overcoming current manufacturing constraints, enabling reliable fresh and hardened performance of LC3 concretes, and supporting broader adoption of calcined clays in the U.S. market.

36 MATERIALS SCIENCE↗

NASA NTRS1979

Failure of underground concrete structures subjected to blast loadings

The response and failure of two edges of free reinforced concrete slabs subjected to intermediate blast loadings are examined. The failure of the reinforced concrete structures is defined as a condition where actual separation or fracture of the reinforcing elements has occurred. Approximate theoretical methods using stationary and moving plastic hinge mechanisms with linearly varying and time dependent loadings are developed. Equations developed to predict deflection and failure of reinforced concrete beams are presented and compared with the experimental results.

Ross, C. A.↗

NASA NTRS1979

Optimization of reinforced concrete slabs

Reinforced concrete cells composed of concrete slabs and used to limit the effects of accidental explosions during hazardous explosives operations are analyzed. An automated design procedure which considers the dynamic nonlinear behavior of the reinforced concrete of arbitrary geometrical and structural configuration subjected to dynamic pressure loading is discussed. The optimum design of the slab is examined using an interior penalty function. The optimization procedure is presented and the results are discussed and compared with finite element analysis.

Ferritto, J. M.↗