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At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

The Global LAnd Surface Satellite (GLASS) evapotranspiration product Version 5.0: Algorithm development and preliminary validation

An accurate estimation of spatially and temporally continuous global terrestrial evapotranspiration (ET) is essential in the assessment of surface energy, water and carbon cycles. The Global LAnd Surface Satellite (GLASS) ET product Version 4.0 (v4.0) based on the Bayesian model averaging (BMA) method was generated to estimate global terrestrial ET. However, certain uncertainty for the GLASS ET product v4.0 limits its application. In this study, we introduced the deep neural networks (DNN) merging framework to improve terrestrial ET estimation for GLASS ET product Version 5.0 (v5.0) generation by integrating five satellite-derived ET products [Moderate Resolution Imaging Spectroradiometer (MODIS) ET product (MOD16), Shuttleworth–Wallace dual-source ET product (SW), Priestley–Taylor-based ET product (PT-JPL), modified satellite-based Priestley–Taylor ET product (MS-PT) and simple hybrid ET product (SIM)]. We compared the performance of DNN method against other merging methods, including GLASS ET algorithm v4.0 (BMA), the gradient boosting regression tree (GBRT) method and the random forest (RF) method, based on 195 global eddy covariance (EC) flux towers covering observations from 2000 through 2015. Validations indicated that the DNN had the highest accuracy among four merging methods across different land cover types, yielding the highest average determination coefficients (R 2 , 0.62), root-mean-squared-error (RMSE, 24.1 W/m 2 ) and Kling–Gupta efficiency (KGE, 0.77) with a of 99% confidence interval. Compared with GLASS ET algorithm v4.0, the DNN improved on the R 2 by approximately 7% (p < 0.01) and the KGE by 10%. Based on the DNN, we then generated 8-day GLASS ET product v5.0 globally with a 1 km spatial resolution from 2001 to 2015 driven by GLASS vegetation and surface net radiation (R n ) datasets and Modern-Era Retrospective Analysis for Research and Applications, Version 2 (MERRA2) datasets. Finally, this global terrestrial ET product provides a valuable dataset for monitoring regional and global water resources and environmental changes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Evaluation of distributed process-based hydrologic model performance using only a priori information to define model inputs

Fully distributed, integrated surface–subsurface hydrological models (ISSHMs) have seen renewed interest due to availability of better software, high performance computing facilities, and high-resolution, spatially extensive data products. ISSHMs are valuable as tools for advancing system understanding as they can resolve multiple processes defined on the plot scale including three-dimensional interaction of surface water and groundwater. Here, we evaluated the performance of an ISSHM, the Advanced Terrestrial Simulator (ATS), on seven diverse catchments across the continental US using widely available data products to define model inputs without calibration. We compare the ATS-simulated streamflow and evapotranspiration with gauge observations and MODIS-derived evapotranspiration, respectively. Using the Kling-Gupta Efficiency (KGE) as metric, ATS with default data products performed reasonably well at 6 of 7 catchments for streamflow. However, in one of those 6 catchments ATS had poor performance on baseflow and ATS’s overall performance was thus judged to be inadequate despite the acceptable KGE. ATS performance for evapotranspiration was good in all 7 catchments using default data products. In the two catchments where ATS streamflow performance using default data products was not acceptable, the performance was significantly improved by using local information on subsurface properties below the soil. We also compare the model-simulated streamflow and evapotranspiration with the Sacramento soil moisture accounting (SAC-SMA) model, a semi-distributed model that was calibrated on a catchment-by-catchment basis. Uncalibrated ATS performance is comparable to the calibrated SAC-SMA model in terms of streamflow while ATS performance is similar to or better (much better in certain catchments) in reproducing MODIS-derived evapotranspiration. Reasonably good performance of ATS without catchment-specific calibration provides new confidence in the ISSHM class of models and community data products as tools for advancing understanding of watershed function in a changing environment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Analysis of the laser welding keyhole using inline coherent imaging

Laser beam welding is a widely used fusion welding process in many industrial applications such as automotive, aerospace, energy, defense, and medical products. Industry has a fundamental need to model the laser welding process to minimize experimental testing and improve confidence in production welds. However, computational models attempting to predict weld formation are limited by an incomplete understanding of the beam-material interactions. As a consequence, these models do not accurately predict the mechanisms associated with laser weld formation. To improve the current state of prediction capabilities, it is vital to better detect/measure the physical aspects of the weld pool during high energy density welding. In this work, a novel real-time laser weld monitoring device using inline coherent imaging (ICI) was used to provide a fundamental understanding of laser weld formation via vaporization. The objective of this work was to investigate and quantify the relationship relating laser weld parameters and the vapor capillary (keyhole) through a state-of-the-art measurement technique. Bead-on-plate laser beam welds were produced with partial penetration on 304L stainless steel, 2205 duplex stainless steel, and Ti-6Al-4V. Keyhole monitoring was performed using a commercially available ICI system to collect keyhole penetration data in real time. These measurements were reconstructed to generate the vapor capillary shape at different welding parameters. Process parameters significantly influenced the keyhole shape and the keyhole root position relative to the process beam. Finally, the keyhole geometry showed distinct differences between the stainless steel alloys and Ti-6Al-4V.

2205↗
DOE OSTI2025

Efficient screening of rare large pit anomalies on polished surfaces using a minimalist sampling scheme

Lawrence Livermore National Laboratory (LLNL) has made significant strides in generating clean energy through its inertial confinement fusion (ICF) experiments. These experiments rely on high-density carbon (HDC) coated shells to encapsulate the fusion fuel. The success of these experiments is heavily dependent on the surface quality of these shells, as even minor imperfections, such as deep pits, can negatively impact fusion yield. Ensuring the required smoothness involves an extensive surface-finishing process that spans approximately 20 stages, making it both time-intensive and resource-demanding. A critical challenge in this process is the need for high-resolution scans to detect rare deep pits, which can be costly and impractical if performed on every shell. This highlights the necessity of developing more efficient scanning methods to optimize time and cost without compromising accuracy. To address these challenges, we introduce a novel approach that employs the multivariate Dvoretzky–Kiefer–Wolfowitz (DKW) inequality to provide a probabilistic upper bound on the error in estimating pit distribution characteristics via a Kernel Density Estimator (KDE). This error bound enables efficient and reliable estimation of pit distribution characteristics at a specified statistical confidence level using a minimal number of surface scans. The integrated DKW-KDE approach was validated through surface-finishing experiments across two batches of HDC-coated shells, demonstrating consistent and robust performance across multiple stages of the surface-finishing experiments. The validation studies suggest that the integrated DKW-KDE approach achieves comparable accuracy in estimating the risk of deleterious large pits with six scans, thus conserving time and resources. Further evaluations show that performance remains consistent across batches and over multiple polishing stages. In conclusion, based on these findings, one can leverage the minimal-scan insights to strategically improve the bottleneck inspection process, thus enhancing the productivity and quality of shell polishing and similar challenging manufacturing processes.

Inertial confinement fusion↗
DOE OSTI2022

INTERFACES. A Program for Determining the 3D Structures of Surfaces Sites Using NMR Data

Dynamic nuclear polarization surface enhanced NMR spectroscopy has enabled the determination of high-resolution structures from surface-supported molecules, including singlesite heterogeneous catalysts. Structure determinations have largely mimicked the approaches used in biomolecular NMR spectroscopy, namely, using distance measurements to constrain a conformational search. These early demonstrations made use of purpose-built software, which has limited the adoption of the technique. Herein, we describe the open-source program INTERFACES (Interpret NMR to Elucidate or Reconstruct the Full Atomistic Configurations of External Surfaces) which automates the analysis of RE(SP)DOR data as well as the structure determination for surface sites. Distances, angles, dihedral angles, complex orientation, and distance from the support can all be sampled to find all structures that agree with the experimental data. A χ 2 metric is used to define the error ranges of the REDOR fits and produce structures with an arbitrary level of confidence. Structural solutions are then provided as both overlays and ORTEP-like probability ellipsoids.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Accelerating nuclear fuel development and qualification: Modeling and simulation integrated with separate-effects testing

In this work, an approach to transform and accelerate nuclear fuel development and qualification is outlined. The approach exploits advanced modeling and simulation at the outset to inform constituent and system selection and to enable integral fuel performance analyses. Analyses using these tools identify and prioritize the most important fuel performance parameters and phenomena for subsequent targeted characterization with separate-effects tests. Separate-effects testing spans out-of-pile and in-pile tests and is meant to iterate with and inform engineering-scale integral fuel performance analyses throughout the development process. Exercising this cycle in an agile fashion will increase confidence in the integral fuel performance predictions while reducing uncertainties. This process sets the stage for executing a much more limited set of well-defined integral irradiation tests designed to validate engineering-scale fuel performance codes and to confirm the performance and safety of the fuel system under prototypic conditions. This approach will reduce the time for development and qualification of a new fuel system, and it will also reduce associated costs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Mechanistic verification of empirical UO 2 fuel fracture models

Standard UO 2 fuel pellets used in light-water reactors fracture during irradiation due to the large thermal gradient in the radial direction. Over the decades, numerous researchers have explored fuel cracking from experimental and modeling points of view. To date, there have been both empirical and mechanistic approaches to predict the number of fragments that form in UO 2 . The empirical models only consider maximum power and burnup as inputs. Existing mechanistic approaches for normal operation have not accounted for irradiation effects. Here, this work employs a mechanistic fuel cracking model using the extended finite element method to explore radial crack formation while including a sensitivity analysis that accounts for the randomization of tensile strength within the fuel, the strength randomization criteria (uniform or volume-weighted Weibull), power ramping rates, computational mesh density, maximum power level, and irradiation (burnup) effects. The results indicate that the uncertainty in this mechanistic modeling approach envelopes the predicted values from three different empirical correlations in almost all cases. This means that, for computationally intensive analyses involving UO 2 fragmentation, the empirical correlations can be used. However, since the mechanistic calculations bound those of the empirical correlations, there is confidence in the applicability of the mechanistic approach developed in this work to generate a correlation for fuel types where limited data exists (e.g., doped-UO 2 , U 3 Si 2 ).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Automatic information extraction from neutron radiography imaging to estimate axial fuel expansion in $\mathrm{EBR-II}$

Approximately 130,000 metal fuel pins were irradiated in the Experimental Breeder Reactor II (EBR-II) during its 30 years of operation to develop and characterize existing and prospective fuels. For many of the metal fuel irradiation experiments, neutron radiography imaging was performed to characterize fuel behavior, like fuel swelling. However, due to the lack of technology or resources, many of the images have not been processed or were processed manually through visual examination. This paper represents first-attempt to develop an image processing algorithm capable of automatically extracting information regarding the degree of fuel swelling from neutron radiography imaging. The algorithm was applied to 120 images of three different metallic fuel pin compositions—U-10Zr, U-8Pu-10Zr, and U-19Pu-10Zr. The algorithm performs operations of image intensity adjustment, image binarization, region finding, and labeling to extract information about fuel swelling. The average growth for U-10Zr was found to be 8.49% with 95% Confidence Interval (CI) [8.33 –8.66%], for U-8Pu-10Zr — 7.50% with 95% CI [7.23 – 7.78%], and for U-19Pu-10Zr — 3.15%, with 95% CI [2.40 – 3.91%]. The results obtained by applying this automatic image processing algorithm are consistent with previously reported studies of the same types of fuels. The automatic image processing algorithm will be expanded to include thousands of available neutron radiography images and different types of fuels to investigate empirical dependencies of fuel swelling, which can be subsequently applied to advanced fuel modeling. Results from this study can later be compared to BISON simulations to further benchmark modeling efforts and develop assessment cases.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Molybdenum and Tungsten isotope compositions of UO 2 fuel pellets: Implications for isotopically enriched taggants

The addition of isotopically enriched taggants to material at the front end of the nuclear fuel cycle could be a powerful tool used to assist law enforcement authorities should material outside of regulatory control be found. Two potential candidates for this purpose are molybdenum (Mo) and tungsten (W) as both elements have five or more stable isotopes and are trace elements contained within nuclear fuel. So there is a concern that Mo and W could undergo isotope fractionation during processes like uranium enrichment and to date, it is unknown if nuclear fuels have natural Mo and W isotope compositions. If Mo and W isotopic variability is present in nuclear fuels, this would hinder the use of these elements as isotopic taggants because it would be difficult to discern the original taggant isotope composition with high confidence. Therefore, a set of 16 low enriched uranium (LEU) fuel pellets from US commercial producers was analyzed using multi collector-inductively coupled plasma mass spectrometry (MC-ICPMS) to determine Mo and W isotope compositions (i.e., 94 Mo/ 92 Mo, 95 Mo/ 92 Mo, 96 Mo/ 92 Mo, 97 Mo/ 92 Mo, 98 Mo/ 92 Mo, 183 W/ 182 W, 184 W/ 182 W, and 186 W/ 182 W). Relative to terrestrial standards, LEU fuel pellets have variable Mo and W isotope compositions, thereby complicating the use of these elements as isotopically enriched taggants. As such, this work demonstrates that the isotope composition of any potential taggant must be well characterized in the base nuclear fuel prior to any taggant addition. Furthermore, these results suggest that Mo and W are not ideal candidates for isotopically enriched taggants.

58 GEOSCIENCES↗
DOE OSTI2025

Mechanistic nuclear fuel performance modeling of uranium nitride

Uranium mononitride (UN) is a nuclear fuel candidate for advanced reactor designs and an alternative being considered for light water reactors due to its higher thermal conductivity and uranium density than UO 2 . As with any nuclear fuel, swelling and fission gas release are important factors for safety, while also being some of the hardest phenomena to predict with a high degree of confidence. Getting a grasp on the gas swelling behavior and release is crucial to lower the barrier for UN utilization. An accelerated swelling rate at high temperatures observed experimentally, sometimes referred to as “breakaway swelling,” further complicates the prediction of fuel performance of UN. A mechanistic model has been developed using a multiscale approach to describe the intragranular and intergranular fission gas behavior. Lower-length-scale calculations have been employed to inform models of the gas and self-diffusion behavior, resolution rate, and bubble shape. Leveraging previous work on high burnup UO 2 , two populations of intragranular bubbles are considered; small bulk bubbles and larger bubbles located along dislocations. The dislocation bubbles were found to be crucial to the overall swelling behavior, and the breakaway swelling transition was associated with the transition in the gas atom diffusion mechanism from an irradiation-induced athermal diffusion regime at lower temperatures to an intrinsic thermal equilibrium regime at higher temperatures, accelerating the growth of the dislocation bubbles. Similarly, the threshold for fission gas release was associated with the grain boundary vacancy diffusivity surpassing the gas atom diffusivity at sufficiently high temperatures, allowing the over-pressurized grain boundary bubble to grow in size and interconnect. Using thermo-mechanical models with the fission gas model, two integral fuel pin assessment cases were simulated. Finally, this work demonstrates the ability of a multiscale approach to accelerate the understanding of advanced fuel forms when experimental data is limited.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Microstructurally validated stable and predictable swelling in low-enriched uranium monolithic U-10Mo fuel mini-plates

Qualification of the low-enriched uranium (LEU) monolithic U-10 wt%Mo (U-10Mo) plate-type fuel system requires a demonstration of a stable and predictable fuel swelling behavior over the anticipated operating conditions of the United States high-performance research reactors (USHPRRs) selected for conversion to LEU operation. This will allow each reactor to develop appropriate safety margins that will retain fuel element lifetime coolability. Additionally, the fuel system must maintain performance attributes when fabricated at a commercial scale. The Mini-plate 1 experiment represents the first irradiation test of commercially fabricated miniaturized monolithic LEU U-10Mo fuel plates. Here, the swelling behavior within this experiment was compared against that of historical fuel developmental tests to reveal that the commercially fabricated fuel performed within the current recommended U-10Mo swelling model's predictions. Additionally, the fuel microstructural evolution was evaluated to link initial conditions to subtle variations detected in the swelling response, providing validation and confidence that the fuel system is robust.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Assessing the viability of a new subsize tensile specimen geometry for evaluation of structural nuclear and additively manufactured materials

The use of subsize specimens in nuclear materials testing has been a subject of ongoing interest due to radiation safety concerns and resource conservation needs. It is also of interest in additive manufacturing (AM), also known as 3D-printing, as subsize specimens can more accurately represent the behavior of the small, intricate geometries often produced using AM. A novel, extremely small geometry, called the Subsize Teeny (SST) was recently developed and is of interest for implementation. Given its extraordinarily small size and the complexities associated with subsize specimen testing, adequate vetting of this geometry is necessary to ensure data quality. Here, a variety of unirradiated nuclear structural materials were tested in the SST geometry and compared against the well-established SSJ3 geometry. In addition, two case studies implementing the SST as a screening geometry for AM materials were also conducted. The question of SST viability was found to be highly nuanced and will often be dependent on the context or application in question. It was determined, however, that the SST is a largely invalid geometry for exceptionally coarse-grained materials or in cases where the physical defect volume equals or exceeds 0.1 % or where the specimen machining parameters result in significant surface alterations. On the other hand, it was determined that the SST may be employed with confidence if the test material is nearly or totally free of physical defects, isotropic, demonstrates homogeneous plastic deformation, and possesses a fine-grained, nearly or totally homogeneous microstructure with at least twelve slip systems.

Additive manufacturing↗
DOE OSTI2025

An integrated approach to examine fuel-cladding chemical interaction in HT9/U-10Zr metallic fast reactor fuels: Coupling machine learning with electron microscopy and local mechanical properties analysis

The metallic U-Zr nuclear fuel alloy has garnered renewed interest as a promising candidate for next-generation sodium-cooled fast reactors. Recent studies and technology assessments have identified several areas requiring improvements, enhanced knowledge, and reliable data to strengthen the U-Zr fuel design basis for qualification and commercial applications. One of the most challenging phenomena impacting this fuel system’s performance is fuel-cladding chemical interaction (FCCI). This work aimed to harvest FCCI data by examining selected HT9/U-10Zr (wt. %) fuel samples of prototypic full-length fuel pins through an integrated approach. This approach integrated scanning electron microscopy (SEM) microstructure characterization with localized mechanical properties examination to deepen understanding of FCCI phenomenon in HT9/U-10Zr fuel system. Particularly, this study focused on MFF fuel pins irradiated at Fast Flux Test Facility (FFTF), which aimed to qualify metallic fuel as a driver fuel for FFTF and to assess its viability for larger-scale fast reactors. Electron microscopy provided high confidence in detecting and distinguishing the different FCCI layers, while small-scale mechanical testing (SSMT) probed the mechanical properties of these layers. SEM examination of a MFF-2 pin 192167, with a time averaged inner cladding temperature (TICT) slightly over 500°C, revealed minimal cladding-side FCCI (cladding wastage). In contrast, significantly thicker cladding wastage comprising two distinct sublayers was observed in samples from the thermally hot MFF-3 pin 193045 and MFF-5 pin 195011 where the TICT ranged from 610-635°C. SSMT indicated complete embrittlement in the sublayer adjacent to the fuel and a tendency toward embrittlement in the other sublayer. Additionally, a new machine learning method was developed, validated, and used to quantify cladding wastage thickness. The machine learning method reliably predicted the wastage thickness across various fuel pins and sample cross-sections. Furthermore, the available cladding wastage data from HT9/U-10Zr fuel system demonstrated a strong temperature dependency. However, the dataset remains small, and ongoing research activities are essential to further understand the FCCI phenomenon and develop a reliable FCCI model for enhanced fuel performance simulation under various conditions.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Natural isotopic compositions of titanium, iron, and nickel observed in commercial fuel pellets – Promising candidate elements for stable isotope tagging

Stable isotope taggants would constitute unique identifiers for nuclear fuel cycle materials, resulting in expedited timelines and high confidence provenance assessments for nuclear forensics investigations. However, reliably identifying and interpreting stable isotope taggants in nuclear materials recovered from outside of regulatory control will largely be predicated on the assumption that the taggant element intrinsic to the untagged nuclear material exhibits natural isotopic ratios. Here, we present high-precision Ti, Fe, and Ni isotope compositions in 13 commercial low-enriched uranium (LEU) fuel pellets to assess the suitability of these transition metals as stable isotope taggants. Our investigations reveal limited isotope variations among the fuel pellets in all three elements, which are consistent with small mass-dependent isotope fractionations, comparable to variations previously reported for natural samples. In practice, isotopically tagged nuclear materials are expected to fall along isotopic mixing lines, since intrinsic background levels of taggant elements dilute the taggant towards natural isotope compositions. Furthermore, the observation that Ti, Fe, and Ni isotope compositions in a suite of LEU fuel pellets are close to or indistinguishable from estimates for the Bulk Silicate Earth demonstrates that a two end-member mixing assumption would be valid for these transition metals, indicating that all three are promising candidate elements for stable isotope tagging. Finally, we present mass balance calculations to quantify isotopic perturbations expected from admixing isotopically anomalous Ti, Fe, and Ni taggants to assess the interplay between elemental and taggant concentrations and find favorable compromises for facilitating successful taggant identification with current analytical methods.

Intentional forensics↗
DOE OSTI2025

Radiation-induced bowing of SiC/SiC composites under neutron flux gradients—integral experimental data for model validation

Here, the radiation-induced swelling of SiC and its composites, including strong dependencies on temperature and dose, can drive significant lateral bowing in the presence of temperature and/or dose gradients. In recent years, simulations have been performed to assess the extent of bowing in SiC composite light-water reactor (LWR) fuel cladding and boiling water reactor (BWR) channel boxes. However, to date, no integral experimental data exist to validate these models. This work provides the first experimental bowing evaluation of three ∼380 mm long SiC composite specimens irradiated under varying neutron dose gradients (∼50°C–60°C, 0.03–0.06 dpa): two tubes (∼9.8 mm diameter) and a miniature BWR channel box (∼30 mm square). The measured radiation-induced length swelling (∼0.3%–0.7% linear) was consistently 10%–21% higher than values obtained from 3D finite element structural analyses with inputs from 3D radiation transport calculations. This discrepancy could be at least partially explained by differences in dose rate (∼10 -8 dpa/s) compared to the literature data (∼10-6 dpa/s) used to establish the dose-to-swelling correlations in the model. Nevertheless, the modeled bowing magnitudes (<2 mm) obtained from finite element analyses and simple analytical equations were within the bounds of the experimental measurements for all specimens. With improved confidence in the ability to predict the structural response and measure the macroscopic deformations, future experiments will target transient bowing under neutron flux gradients at representative LWR temperatures and assess whether grid spacers can mitigate the tens of millimeters of bowing that would otherwise be expected in ∼4 m long LWR components.

bowing↗
DOE OSTI2025

Expanded method for the determination of burnup in nuclear fuels using multiple neodymium isotopes

Established methods for the determination of burnup in nuclear fuels commonly rely on the measurement of 148Nd in the spent fuel in concert with known fission product yields to determine the atom percent of fissions in the fuel. This isotope of neodymium is used for various reasons, including chemical and radioactive stability, ease of measurement, and low rates of formation and destruction due to neutron flux apart from fission. However, careful calculation of effective cumulative fission yields and correction factors for (n,γ) capture reactions allows for additional stable and long-lived isotopes of neodymium to be used to provide additional independent measurements of burnup, reducing statistical uncertainty. This method was developed and successfully applied to measure the burnup of compacts from the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program. The mean burnup measured using 143Nd, 145Nd, 146Nd, 148Nd, and 150Nd was statistically observed to be the same as that measured using 148Nd alone, but the statistical uncertainty in the measurement was reduced by a factor of 2, providing a tighter confidence interval in the final results.

Helmreich, Grant [ORNL] (ORCID:0000000330464394)↗
DOE OSTI2024

Reassessing early-age strength development of high-volume fly ash concretes for precast buildings

Increasing beneficial use of fresh or landfilled fly ash as a replacement for Portland cement can be more challenging for the construction of precast buildings or similar applications requiring rapid strength development. Therefore, the framework presented in this paper aims to reassess high-volume fly ash concretes but in the context of facilitating more sustainable precast buildings. More specifically, the framework was used to characterize strength development of concrete mixes with a target minimum 24-hour compressive strength of 24.1 MPa (3500 psi), selected as an example strength development metric to demonstrate the framework, and comprised of 40% Class C, Class F, and landfilled (harvested) fly ash – as a high-volume replacement of Type III or Type IL cement. High-early strength was driven by optimized dosages of commercial grade gypsum and accelerating admixtures, in addition to optimal aggregate packing and mix proportioning strategies. Early-age mechanical properties including compressive strength, modulus of rupture, and modulus of elasticity were reevaluated within 24 hours of batching with respect to common precast production demands. Simple data analyses were then used to highlight cases where currently accepted design provisions for the aforementioned properties are either overly-conservative or unconservative with respect to test data. Furthermore, the framework and demonstration of example mixes presented herein aim to promote confidence for using larger fractions of fresh or landfilled fly ashes for precast buildings to further enhance environmental benefits without sacrificing pertinent early-age structural performance.

42 ENGINEERING↗
DOE OSTI2025

Multi-faceted framework for extrapolating early age flexural strength to facilitate rapid lifting/handling of high-volume fly ash precast members

Maintaining adequate early-age structural performance for precast concrete components has grown in importance as more sustainable mix designs become more widespread. Achieving high-early flexural strength is particularly crucial to facilitate rapid removal of hardened concrete components from formwork, often within 24 h after fresh concrete placement. Limited research has assessed the effectiveness of traditional design methods in correlating flexural strength with compressive strength for next-generation mix designs, or demonstrated extrapolation of such material performance to larger-scale structural tests. This paper presents a multi-faceted framework to reassess early-age flexural strength for concretes made with relatively high proportions of fly ash from both fresh and harvested sources. Here, the framework provides several pathways, from which the user can select based upon available resources and the specific application, to improve accuracy of early-age cracking moment calculations. Furthermore, the scope includes evaluation of strength performance under curing conditions emulative of those in a precast facility, recommending modulus of rupture equations which are more performance-driven than current design provisions, and experimental tests on prefabricated concrete beams to validate the proposed methodologies. Correlations of early-age strength with both concrete age and maturity measurements compare the effectiveness of utilizing in-situ data to further enhance the prediction methods. Ultimately, the proposed framework helped reduce errors when calculating cracking moment capacity at early ages by tailoring calculations to reflect mix-dependent behavior. Furthermore, most estimates of cracking moment were within 25 % of their corresponding experimental test results, thus promoting confidence for using these strategies with high-volume fly ash precast structures.

42 ENGINEERING↗