US20210039997A1 Palm Oil Fuel Ash in Concrete

us: us) United States 2) Patent Application Publication co) Pub. No.: US 2021/0039997 Al oy oy ~ ow ey @ SALAMI et all ALKALL-ACTIVATED CONCRETE CONTAINING PALM OIL FUEL ASH Applicant: King Fahd University of Petrol and Minerals, Dhahran (SA) Inventors: Babatunde Abiodun SALAMI, Dhahran (SA); Megat Azmi Megat Johari, Diabran (SA); Mohammed Maslehuddin, Dhshran {SA}, Zainal Aritia Ahmad, Dhaka (SA) Assignee: King Fahd University of Petroleum ‘and Minerals, Dhara (SA) Appl. Now 16/533,014 Filed: Aug. 6, 2019 1003999741 2021 (43) Pub. Date: Feb. 11, 2021 Publication Classification GI) Ime, coi 2926 (2006.01) CosB 1406 (200501), cous TAs 2006.01), (2) US.C, cr oat 2826 (2013.01); Coss 2201/50 (013 01); Co4B 7/44 (2013.01), COSB 14706 (01301) on ABSTRACT A concrete composition that includes () a treated palm cil fel ash, wherein the treated palm oil fuel ash is the only binder presen, (ia fine agarezate, (i) a couse aggregate ‘and (iv) an alka activator containing an aqueous solution sodium hydroxide and sodium silicate. A cured conere ‘made from the concrete composition is also disclosed with advantageous compressive strength properties,Patent Application Publication Feb. 11,2021 Sheet 1 of 3. US 2021/0039997 AL Fig. 2 ‘Treatment of palm oil fuel ash (POFA) Collection of raw POFA from Nikeng Tebal, Malaysia Drying of POFA (e.g. at 105 °C for 24 h) to remove any inherent moisture Sleving (e g., through 300 jum sieve) to remove coarse and ‘unwanted materials POFA passing through eg, 300 jum sieve ground in ball mill (eg. for 6h) “Heat treatment of ground POFA (eg, at 550 °C for 2 h) to reduce carbon content and prevent glass crystallization ‘Re-grinding in ball mill (eg. for 6 h) to form treated palm cil fuel ash (TPOFA) Characterization of treated palm oil fuel ash (TPOFA) e.g. using XRD, XRF Selection of TPOFA to produce POFA-engineered cementitious composite (POFA-EACC)Patent Application Publication Feb. 11,2021 Sheet 2 of 3 US 2021/0039997 AI Fig. 4 aeUS 2021/0039997 AI Feb. 11, 2021 Sheet 3 of 3 Patent Application Publication Fig. 6US 2021/0039997 AI ALKALL-ACTIVATED CONCRETE CONTAINING PALM OIL FUEL ASH BACKGROUND OF THE DISCLOSURE, ‘TECHNICAL FIELD 10001] The present disclosure relates to alkali-etivated ‘concrete compositions that include palm oil fuel ash, and ‘cured conerete made therefrom, DESCRIPTION OF THE RELATED ART [0002] The “background” description provided herein is Jor the purpose of generally presenting the context of the disclosure. Work of the presently numed inveators, to the ‘extent its deserbed in this background section, as well as, aspects ofthe description which may not otherwise qualify as prior art at the time of fling, are neither expressly or impliedly admited as prior art apsins the present disclo- [0003] According to guidelines ofthe Intergovernmental Panel on Climate Change IPCC) and other agencies of the United Nations, mitigating CO, emissions is atop pririty {or combating rising global average temperatures. One ofthe practical and sustainable means to achieve the limits set for the global average temperature at the UN conference of partes (COP23) is for the cement industry to lower the production of Portland cement and to develop an econo: cally- and eavironmentally-fieadly substitute. CO, is a byproduct produced during. the production of Portland ‘cement, specifically during the formation of clinker (intermediate product) sing elevated temperatures inside a kid, Where cleium carbonate from ealeiti-rich material is ‘converted into time and CO. In fac, in 2015, Portand ‘cement generated around 28 billion tons of CO,, equivalent to 8% ofthe total CO, generated globally The high levels of ‘CO, emitted from cement production is only expocted 10 ‘worsen as global urbanization and economic development increase with higher demand for new buildings and infra 10004) Therefore, the cement industry has begun research Jno energy elicient cementitious materials 1 replace ‘cements such as ordinary Portland eement (OPC), encour aged by changes in policy, technology, and new opportuni- tiesto tse profits and eit costs through decreasing grcen- house gas emissions. However, only limited progress has been made so far 10005] One type of technology being explored is alkali activated concrete (AAC) using aluminosilicate binders having pozzolanie behavior, owing in part o the vast slumino- silicate material options. AAC is produced using « binder tenersed from the reaction between aluminosilicate procure or and a highly alkaline solution, which results i litle ‘energy dissipation during production, Many binding mate- Fials have been used in alkali activated coneretes, such as metakaotin, fly ash, natural pozzplan, and other materials ‘generated from industrial and agriculteral activities, such as blast furnace slag and rice husk ash 0006} Another ofthese aliminosiliate materials is palm oil fel ash (POF), at agricuiural waste material produced from the buming of palm fibers, empty fruit bunches and kernel shell. The ash produced after buring of these waste materials (POFA) hus been historically disposed of indis- ‘riminaely in lands, eausing lost profits snd health Feb. 11, 2021 cerns 10 nearby’ inhabitants, Vast volumes of POEA are produced in Malaysia, Thailand and Indonesia, In fact, alobal palm oil production has inereased from 15.2 million {ons in 199S to 54 million tons ia 2012 and itis expected to row by more than 25% by 2020 ta global level of more than 68 million tons (European Palm Oil Alliance, 2014). ‘Therefore, finding constrictive nnd profitable uses for the major waste byproduct, POPA, remains of interest. How ever, the use of POFA asa binding material in cement mortar has significant challenges. For instance, he chemical com position of POFA is characterized by a high amount of SiO, (Go varying, quantities depending on the region and treat ment), and low quantities of AIO, and CaO, which causes ‘ond formation inadequacies needed for high Strength, ham- pering its implementation as a binder. [0007] Asa result, many aluminosilicate materials such as palm il fue ash (POFA) have been used asa supplementary ‘cementing material (asa partial replacement of cement), bit Fave not boon use as the sole bind (complete replacement {or cement) in concrete. [0008] In view of the forgoing, one object of the present disclosure is to provide conerete compositions that contain palm ol fuel ash (POFA), and cured eonerees made therefrom with advantageous compressive strength and durability properties. Such concrete compositions may be made with OFA as the only binder material, which has the benefit of redneing POFA waste volumes in lndills, conserving nate ‘ail materials, and reducing CO, emissions and energy on sumption required for cement manufacture. BRIEF SUMMARY OF THE DISCLOSURE [0009] Accordingly itis one objet ofthe present invention ta provide concrete compositions containing treated palm oil Juel ash as the only binder material [0010] It is another object of the present disclosure 10 provide cured concrete, formed from curing the conerete ‘composition, with a high compressive strength, [0011] These and other objects, which will become appar- ent during the following. detailed description, bave boon Achieved hy the inventors’ discovery that adequate gradation ‘of a treated palm oi fuel ash binder and aggregate enables the POFA material to be wed asa complete replacement for cement such as OPC: [0012] Ths, the Present Invention Provides: [0013] A concrete composition that includes (2) 2 treated palm oil fuel ash, wherein the treated palm ol fuel ash isthe only binder present, Gi) a fine aggregate, (ii) a course aggregate, and (i) an alkali activator containing an aqucous solution of sodium hydroxide and sodium silicate. [0014] In some embodiments, the teeated poli ol uel ash fs present in an amount of 20 to 30 wt. %, based on a total ‘weight of the concrete composition, [0015] In some embodiments, the tested palm ol fuel ash Js obtained sequentially from drying raw palm il fuel ash at 80 to 120° C, sieving to particle size of less than 300 jm, fist mechanical ball milling, aleining at 500 to 600°C, fd a second mechanical ball milling [0016] Insome embodiments, the treated palm ol fuel ash has median particle size (d,} of 0.5 to 2.0 um. [0017] In some embodiments, the treated palm ol fuel ash contains, as constituent oxides, 60 t0 72 wt. % SiO,, 4 to 8 WL %ALO,, 3107 Wh % FesOy, 310 8 wt. % CaO, WL % MBO, 3107 wt. % KO, 0.2 10 0.5 wt. % SO, 0.US 2021/0039997 AI 025 wt. % NaO, and 1 10 5 wt % oF P.O, each based oa total weight ofthe tated palm cil fuel ah, [0018] In some embodiments, the treated palm ol fuel ash ‘contains, as constituent oxides, 66 to 68 wt. % SiO,, 6 10 7 WL % ALO,, 510 6.5 wt % FeO, 5 106 wi. % CaO, 2 1 35 wt % MgO, 45 10 6 Wt % KO, 03 10 035 wt % 50,, 0.18 100.2 61, %Na,0, and 3104 Wt, % OFP,O,, each based on a total weight ofthe treated palm oil fuel as. [0019] In some embodiments, the tested palm ol fuel ast has a fosson inition (LOD of less 3 wi, %, base on a total ‘weight ofthe treated palm ol vel ash, and a specific surface tea of 1.4 0 1.6 ma. 0020] In some embodiments, a weight ratio of a com- binned weight of the coarse aggregate and the fine agpregate to the treated palm oil fel ash #8 [1 to 2:1 [0021] In some embodiments, the fine aggregate hus fineness modulus of 18 to 2.1 and saturated surface dry (SSD) spevtie gravity of 25 to 2.7. 10022] In some embodiments, the coarse aggrepate has @ saturated surface dey (SSD) specific eravity of 24 to 26. 10023] In some embodiments, the coarse aggrepate has @ bimodal particle size distribution with a fist mode particle size of 4 t0 6 mm and second mode particle size of 210 3 rm, anda wherein weight rato of coarse aaregate having the first mode particle size to coarse agaregate having the second mode particle size is I: ta 3:1 10024) In some embodiments, a weight ratio ofthe course aregate tothe fine aggregate is 1:1 to 2:1 10025] In some embodiments, the alkali activator is formed fom an aqueous solution of sodium hydroxide having a sodium hydroxide concentration of 10 t0 14 moVL. 0026] In some embodiments, a weight ratio of the alkali activator to the tated palm oil fuel ash is 03:1 10 07:1 10027] In some embodiments, a weight ratio of sodium silicate to sodium hydroxide is 1:1 t0 3:1 10028] In some embodiments, the concrete composition has weight ratio of water tothe teat palm ol fuel ash of| 0,06 10 0.98, 0029] In some embodiments, the concrete composition ‘consists of the treated palim oil fel ash, the coarse aggre~ ‘zac, the fine aggregate, sodium hydroxide, sodium slat, and water. 10030] A cured concrete containing the eonerete compo- sivion in cured form, In some embodiments, the cured ‘concrete his a 28-day compressive strength of 33 0 49 MPa, [0031] In some embodiments, the eured concrete has @ Unit weight of 2200 to 2300 Kyla. The foregoing pan- ‘arp have been provided by way of general intrcuction, ‘and are ot intended to Fimit the scope of the following claims. The described embodiments together with further ‘advantages, will be best understood by reference o the following detailed description taken in conjunction with the ‘accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS 10032] Amore complete appreciation ofthe disclosure and many of the attendant advantages thereof will be realy ‘obtained as the same becomes beter understood by refer. ‘ence to the following detailed description when considered Jn connection with the accompanying drawings, wherein: 10033] FIG. 1 is an image of typical palm oil fuel ash (POFA) dumping site near to palm oil mill, Feb. 11, 2021 {0034} FIG. 2 is owehart fora treatment and prodvction process for making tated POFA(IPOFA) vied in ners composition: [0035] FIG. 3 isan image of raw POFA oded into an oven for dying: {0036} FIG. 4s pictoral view ofa mechanical bell mil ‘with (0 mills operdting simultaneously {0037} FIG. § is an image of ground POPA after oven Grying and grinding but before best tsatment in ‘persed furnace, where the POP as black appearance: (0038) FIG. 6 isan image of eaeined POFA (ater heat {ewatment in a gas-oporated larace), where the POFA has a By appearance DETAILED DESCRIPTION OF THE EMBODIMENTS 0039] Embodiments ofthe present disclosure will now be eseribed more fully hereinafter with reference to the accompanying drawings, in which some, but not all of the embodiments of the disclosure are shown, Deiinitons [0040] As used herein, the tems “optional” or “optionally” means thatthe subsequently described event(s) can oF feannot occur oF the subsequently deseribed components) may or may not be present (eg. 0 Wt %). [041] The plarase “substantially fee", unless otherwise specified, describes a particular componeat being present in ‘an amount of less than about 1 wi. #%, preferably Tess than about 0.5 wt. %, more preferably ess than about O11 wt %, ‘even more preferably less than about 0.5 wi. % yet even ‘more preferably 0 vt. %, relative to a total weight of the ‘composition being discussed [0042] ‘The term “comprising” is considered an open- fended! term synonymous with terms such as including, ‘contining or having and is used herein to deseribe aspects of the inveation which may (or may not) include additional fcomportens, functionality and/or stractare. Terms such as “eonsisting essentially of” are used to identity aspects ofthe invention which exelie particular components that are not ‘explicitly recited in the claim but would otherwise have a ‘material effect on the basic and novel properties of the fsoncrete composition in either a dry, wet or eured form. Basie and novel properties of the present disclosure include, but are not limited to, the strength such as compressive strength, curing time, slump, workable flow, and viscosity. ‘The term “consisting of" describes aspects ofthe invention in which only those features explicitly recited are included and thus other components not explicitly or inherently included are excluded. [0043] As used herein, the term “binder” refers to a ‘composition or substance with one or more constituents that is capable of binding materials together, once set. While a “binder” classically refers to materials or mixtures of materials that are “cements” (eg., Portland cement), in the present disclosure, a "binder" may be a cement or any other ‘material that is capable of forming cement of capable of forming materials with cement-ike binding properties. ‘Therefore, included in the definition of “binder” are those materials that have litle to no cementitious value by them selves but which wil, in finely divided form and in the presence of water, reat chemically with certain chemicals present in the conerete composition to form compouUS 2021/0039997 AI possessing cementitious properties. For exan fd burned onganic mater resides (eg. fy fom silicon smelting, highly reactive metakaolin, palm oil fuel ash, date palm ash, ete.), while not considered coments", are considered to be “binders” in the present disclosure, [0044] As used herein, a “concrete composition” refers 10 workable mixture comprising. water, sgeregate (e. ‘course and fine aguregate), and binder, which has not bees ‘cured/seVhardened, but which is eapabe of being cured set hardened to form useful building/stretural materials such as ‘concrete blocks. As used herein, a “cured conerete” refers t0 ‘8 eured/sevardened form of the concrete composito which has formes! into a hard matrix or stone-like material ‘and is distinguished from the eonerete composition i that it ‘0 longer workable, 10045] As used herein, “total aggregate” or “TA” refers t0 the total amount of coarse aggregate and fine aggregate ‘employed in the conerete composition and cured concrete. ‘Concrete Compositions [0046] In an effort to reduce CO, emissions, the cement industry has timed to replacing cement binders such as ‘ondinary Portland cement with low cost burned agricultural waste products possessing binding. properties. However, ‘even when used as a partis) cement replacement, such bumed agricultural waste products often impart inadequate strength properties (e,z, compressive stength) to the con- ‘rete or mortar, once cured. Such inadequacies are exacer- bated when attempting to completely replace cement with bumed agricultural waste products, [0047] Thus, the present disclosure provides a concrete ‘composition (specially analkali-etivated conerete, AAC) jn which the only binder present is a treated palm oil fuel ash, and which sets into high compressive strength cured ‘concrete. The concrete composition yenerlly comprises, ‘consists essentially of, oF coasists ofa trated palm cil fuel ‘ash as binder, a coarse aggregate, a fine aggregate an alkali activator of sodium hydroxide and sodium silicate, and water The concrete composition may optiomilly contain one ‘or more additives sch as a strength enhancer, an accelerator, ‘a retarder, a plasticizer (ea superplasticize).a pigment, ior, a bonding agent, and a reinlorcing Palm Oil Fuel Ash (POFA) 10048] The oil palm is tallstemmed tee which belongs to the family Arecaceae (commonly known as palins). Oi palm tes, primarily the African ol palm Elaeis guineonss, fn toa lesser extent the American oil palm Elacis oeifera ‘and the maripa palm Adafer maripa, are cultivated for theie palm oil producing fruit, The countries inthe equatorial belt that cultivate oi palm are Benin Republic, Colombia, Fewa- ‘dor, Nigeria, Zaire, Malaysia, and Indonesia, of whieh Malaysia is the largest producer of palm oil and palm oil products (around 47-51% of the words exports of palm oi Jn the palm oil industry, palm ol is extracted from the fruit and copra of the palm oil tee er the extraction process, ‘waste products sueh a palm cil fibers, shells, and empty fist brunches are buried as biomass boiler fel at $00 0 1,000° C. to boil water, which genecates steam to power ‘urine for supplying eletrcal energy tothe entire palm oil nil extraction process. Usually, the palm oil waste product Feb. 11, 2021 ‘and empty frat bunches, although these percentages may of course vary. The resulting ashy, combustion byproduct is palm oil fuel ash (POFA). which constitutes about 5 wt, % of solid waste produets formed ‘during pal oil processing. POPA does not have sulicient ‘nutrient value to be used as fertilizer and has traditionally been dispose in apen fields (profits). [0049] The inventors have found that palm oil fuel ash, specifically palm oil fuel ash which is treated in a certain ‘way, cane tsed a full replacement binder forcement in concrete compositions without adversely affecting the compressive strength of the cured concrete, when used in combination with an alkali activator [0080] “Raw palm oil fuel ash, thats, pli ol uel ash as itis formediteceived from the cil palm boile, typically has {oo high a carbon content (cause hy incomplete burning of the residue) for use as an acceptable binder. Raw POFA ‘ypically also has high moisture content of from 31019 wt oF 410 15 wt. %, oF 5 to 10 wt. % water, based on a total \Weight ofthe POFA, and a elatively large particle size, for example median panicle size (da) of $5 10 75 ym, preferably 60 10 70 um, preferably 64 to 66 yum. [0051] In preferred embodiments, the palm oi fuel ash utilized herein is treated palm oi] foc ash, which is palm oil fuel ash which has been subjected to. combination of dying, sieving, ball milling, and calcining. Briely treated palm oil fuel ash may be formed according to the following procedure [0052] ‘The raw pati oi fuel ash obtained fom a pal oil production Lacility (eg. palm oil mill, United Oil Pals Industries Sda, Bhd. in Nibong Tebal, Penang, Malaysia) ‘ay first be dried, for example, in an oven at 8010 120° C., preferably 9010 110°C., preferably 95 to 105°C., preferably bout 100! C., to reduce the moisture content to below 5 %, preferably below 4 wt. %, preferably below 3 wt. %, preferably below 2. %, preleraby below Iwt.%, The a? pal oil fuel ash may be dried for any amount of time that provides an adequately dried produc, typically, for drying {imes of 12 0 48 hous, preferably 16 0 3¢ hours, preferably 20 to 30 hours, preferably 24 hours [0053] The resulting dried palm oil fuel ash may then be subjected to sieving through one or more sieves of different Size, preferably to oF more sieves of different size, Tor ‘example, sequentially through sieves of decreasing size to remove vourser and unanted particulates. In_preterred embodiments, the dried palm oil fuel ash is sieved sequen- ‘ally through sioves of deereasing size, preferably though fa sct of two sieves of decreasing size, t9 provide sieved POFA having a particle size of less than 400 pum, preferably Jess than 350 um, preferably less than 300 ym. For example, the dried POFA may be sieved sequeatilly through a set of 600 jim snd 300 yun sieves, to provide sieved POFA containing no particles above 300 pm. Altemately the POFA say be sieved immediately upon removal from the kila or boiler without intermediate drying. [0054] ‘The resuiting sieved palm oil fuel ash may then be subjected 10 a first mechanical ball milling procedure to rece the particle size and/or to inrease the srface area of the ash, Any type of ball milling apparatus known %0 ‘ordinary skil inthe art may be employed, including, but not Timited to, a standard ball milla planetary mill a Vibration sail, an at tstiring bal mill,» pin ei, or a rollingUS 2021/0039997 AI individually selected from agate (eryptocrystlline silica) ‘corundum (A1,0,), ziconium oxide (Z+0,), stainless stel (Fe, Cr, Ni), tempered steel (Fe, Cr), and tungsten earbide (WO), preferably stainless steel (eg... SS 316). In some ‘embovdiments, the balls employed inthe ball milling operation havea sizeof from 6 10 32 mm, preferably 8 1028 mu, preferably 100 24 mm, preferably 12 to 20-mm, preferably 8 variety of ball sizes sre employed for the hall milling ‘operation, 10085] The following ball milling parameters may be lulled. The ball to powder ratio (BPR) of charge ratio represents the weight ratio ofthe milling balls to the POF ‘charge, Various BPRs may be employed, but typically a BPR may range from I: 10 10:1, preferably 2:1 to 9:1, preferably 3:1 w 8:1 preferably 4:1 10 7:1, preferably S:1 to 6:1. The sieved palm oil fuel ash may be ball milled ata rotational speed of 100 to 600 mpm, preferably 120 to $00 rpm, preferably 140 to 400 rpm, preferably 160 t0 300 rpm, preferably 180 t0 200 spm. The milling time may also Influence the product morphology and particle size. Suitable nilling times that may be practiced Herein range from 1S minutes 1 8 hours, preferably. 30 minutes 10 6 hours preferably 1 to $ hours, preferably 1.5 to 4.5 hours, prefer ably about 2 to 4 hours although shorter or longer milling times may also be practiced. Further, the sieved palm ol fuel ash may be ball milled in various atmosphers, for example jn some embodiments, ball milling is performed in ai (or & enerlly oxygen-containing atmosphere, eg. which Includes any atmosphere that contains a least 20%, prefer ly a least 40%, preferably at least 60%, preferably atleast 80%, preferably’ at least 90%, preferably at least 95%, preferably at last 99%, or about 100% oxygen by volume). Atematively, ball milling may be carried out under an inert ftmosphere such as under nitrogen of angon, preferably argon. The resulting product may be refered fo herein as round palm oil fuel ash or “GPOFA". In general, the ‘GPOFA has 4 median particle size (Ws) of 28 t0 3.5 um, preferably 2.9 to 3.1 um, preferably 2.96 to 3.0 um 10086) AC this stage, GPOFA sil contains a relatively high ‘amount of unbumed carbon, with a loss on ignition (LOD of treater than 8 wi. Ye or grater than 9 WT, 9, oF greater than 10 wt. 96, and a correspondingly fow amount of constituent ‘oxides usefil for enhancing binding properties (see Table 1 for an example chemical constitution of GPOEA). To remove the unburned carbon content and to provide an ash material wth improved porzaolanic properties, the GPOFA is preferably calcined. The calcination may be performed in @ Jumaee, for example, a ges-powered furnace. The caleins tion may be performed using a pre-set temperature program ‘or asing other variable temperature systems known by those ‘of ordinary skill in the art. The GPOFA may be ealeined under isothermal conditions or under variable temperature onditions. typically ata temperature range of 400 to 900° » preferably 425 to 850° C., preferably 450 to 800° C., mare preferably 475 to 750° C., preferably 500 to 700° C. preferably $50 © 600° C. ‘The caleination is typically performed for 20 minutes (© 8 hours, preferably 40 minutes 1 6 hours, preferably 60 minutes to 4 hours, preferably 80 inutes 1 3 hours, preferably 90 minutes 10 2 hours though shorter of longer calcination times may also be used herein 10087] | While the calcined palm oil fel ash may possess adegqate binding capabilities when employed as a partial ‘cement replacement, or ina Blend (binary, ternary, ee.) with Feb. 11, 2021 other binding materials (ely ash, ground blast furnace slag, silica fume, metakaolin, etc), it has been discovered that subjecting the calcined palm cil fuel ash to a second ‘mechanical ball billing procedure provides a palm oil fuel ash product withthe highest performance (refered to henein ‘as rated pal oil fuel ash of “TPOFA"), which enables its ‘use as fll coment replacement, and without the need for ‘addtional binders The parameters ofthe second ball milling procedure are as described for the fist ball milling proce: {dare above. The parameters used (dhe typeof equipment, the ‘materials used forthe vials, the materials used forthe balls, the bal size, the BPR, the rotational spesd, the milling time, the milling atmosphere) for the fist ball milling and the sovond ball milling may'be the same, or differen, preferably the parameters used for the first and second ball milling ‘operations are the same. [0088] Treated palm oil fuel ash (TPOFA) may vary in terms ofthe percent of constituent oxides present depending fon g number of factors, such as the type of oil palm tree cultivated, the soureeTocation ofthe oil palm tre cultivated, the relative proportion ofthe waste prods (palm oil fiers, shells, anc empty fit brunces) combusted to produce the POFA, the combustion conditions, as well as the pos combustion processing, ete. The teated palm oil fuel ash used herein generally comprises, consists of, or consists essentially of, SiO, AI,O,, Fe,0,, CaO, MgO, K,0, $0, 1a,O, and P.O, In prefered embodiments, the treed pala cil fel ash utilized in the present disclosure has a total ‘entent of SiO, LO, and Fe, that complies With ASTM (C68 class F standards for pozzolan, whichis incorporated herein by reference in its entirety. The present disclosure contemplates using # wide variety of treated palm oil fuel fash materials, with the following constitutional makeup being preferred [0059] In some embodiments, the treated palm el fuel ash has a weight percentage of SiO, of 60 10 72 wt. %, prefer ably 61 10 71 wi. %, preferably'62 to 70 wt. e, prelerably {6310 69 wt. %, preferably 64 fo 68 wt. %, preferably 65 10 67.5 wt. %, preferably 66 10 67 wt. %, hased on a otal ‘Weight of the teated palm oil fuel ash. [0060] In some embodiments, the teated palm ol uel ash ‘has a Weight pereentage of AI,O, of 4 to 8%, %, preferably 4.510 7.5 wt. %, preferably 5 107 wt. %, preferably 5.5 t0 (68 wt. %, preferably 6 10 6.5 wt. %, based on a total weight of the treated palm ol fuel ash [0061] In some embodiments, the treated palm ol fuel ash has a weight percentage of Fe,O, of 3107 wt. %, preferably 3.5 to 6.5 wt. % preferably 4 406.3 wt. %, preferably 4.5 to 6.1 wt.% preferably’ 5 to 6 wi. %, preferably 5.5 (0 5.8 wt 6, based on a foal weight ofthe tested palim oil fuel ash [0062] In some embodiments, the tested palm ol fuel ash thas a Weight percentage of CaO of 310 8 Wt %,3.5 10 T Wt 6, preferably 4 0 6.5 wt %, preferably 4.5 10 63 wt %, preferably 5 t0 6.1 wt %, preferably 53 to 6 wi %, preferably 55 to 58 wt %, based on a foal weight of the treated palm cil fl ash. [0063] In some embodiments, the treated palm ol fuel ash Jas a Weight percentage of MgO of Ito 5 wi. % preferabl 15 10.45 wt. %, prelerably 2 to 4 wt. %, preferably 2.5 to 38 wt. %, preferably 3 t 3.5 e %, proferably 3.1 103.2 we 6, based on a total weight ofthe treated palm ol fuel ash [0064] In some embodiments, the tested palm ol fuel ash basa weight percentage of KO of 3to 7 wt. preferably 3.5 106.5 wi. %, preferably 4 10 6 wt. %, preferably 45 10US 2021/0039997 AI 5.8 wt. %, preferably 0 54. % preferably 510 53 wt 6, based om total weight of he eat palin oil fel se {0065} In some embsimens the tested pal ol fel ash has a weight percentage of SO, of 0.2 t0 05 wt. %, preferably 0.25 to 0.45 ot, prckebly D3 to O. wi. % Preferably 0.31 100.38 wt. preferably 0.3210 0.38 Wt % Based on total icight of the tated pln oil Sul ash {0066} In some embodiments, the ested pam ol fuel ash fas a weight percentage of Na,O of 01 40 025 wi. %, preferably 0.13 00.25 wt. % preferably 0.15 0 0.22. %, preferably 0.17 0 0.21 wt %, preferably 0.18 to 0.2 wt, %, Based on total ight of the Wate palm il fel ash 0067) Insome embodiments the este pam oil fuel ash has a weight percentage of P,O, of | to § Wt preferably 2to dwt %, prefebly 310 3.8'wt %, preferably 3.21036 WU %, prefoubly 3.3 403.8 wi. 8, based on atta weight ‘ofthe tated pal olf ash 10068] In some embodiments, the ested pain ol fel ash ‘ofthe present disclose has lesson ignition (LOD of ess than 4. %, preferably less than 3 wt %, preferably less than 23 wi. 56, preferably less than 2.4 wi. % prefenbly Joss than or gual t 23 1 based ona total Weight ofthe teat pal oil uel ash 10069 "In prefered embesiments, the weated palm oil fel ash comprises, as constitvent oxides, 66 0 68 W186 Si 6107 WH ALO, 51065 WL 6 FeOy.5 196 WI. % C30, 2.5 1035 wi. % MgO, 45 196 W1.% K.0, 03 100.38 wt ¥680,,0.18 w 02 WL %Na,0, anl 31 4 WE % of P.O, ‘each based on total weigh ofthe treated palm ol fel ash 10070] Insome embodiments, the tated pam ol fel ash has median price sie (a) oF Oto 20 pa, preferably (06 101.8 um, preferably 0-7 6 1. yn, peferably 08.01 tum, preferably 0.9 (0 1.2 ym, preferably 1.0 to Ld preferably 1.068 ym. [0071] Insome embodiments, the rested pam ol fel ash hava specific srface are of 1410 15." preferably 138 10 1.58 mig, preferably 1S to 156 mi, prefembly 151 to 154 mela, preferably 1.52 0 183 m/e 10072] “The west palm oil fac ash may be used as & paral replacement of cement or may be used in combina tion with one cr more other binders (ioussed belo) in & binder blend. Therefore, in sich circumstances, the teated pal oi flash may be employed i an ameun’ of yp 30 ‘81%, preferably upto 25 Wt %, preferably up to 20°. %, Preferably up 10 15 wt. % preferably sp to 10 wt % preferably up 0 5 wt. %, preferably up to 1 wt. preferably up to 08 wt *%, based om a total weight of the concrete ‘empostion. However, the treated palm oil fel ash may be ‘advantageously employed as a compete cement replace ment and wherein the TPOFA isthe only’ Binder presen Tins, in prefered embodiments, the Weuted pum Oi fuel ash is the only binder present, and is employed an mount (0120 10 30 wt. %, preferably 31 to 29 wt % preferbly 22 to 28 wt. %, preferably 23 0 27 wt. 9%, preferably 28 to 26 W626, preferably 25 wt. %, based on a total Weight oF the concrete composition. {0073} In the preset disclosure, other binders which may he optionally included in the concrete composition, but which are preferably excided frm the concrete compos tion inclale any cement andlor pozzolan/bueed organic tater residues (other than TPOFA) cspable of pradicing cementlike binding properties {0074} Exemplary cements may be any hydauic cement ‘or 9 aon-hydratle cement, for example, Ordinary Portland Feb. 11, 2021 ‘Cement (OPC) type I. type Hl type IIL, type IN, type Ve ype Ia, type Ila, type Ila ora combination thereof (in aecorlance with the ASTM C150 standard); Pordand fly ash cement; Portland Pozeolun cement: Portund silica fume cemeat: masonry cements; EMC cements; stcoos; plastic cements: expansive cements; white blended cements; Pozzolan-lime coments; slag cements; slag-fime coments; supersulfated cements; calcium aluminate cements; calcium sulfoalum fale cements; geopolymer cements. Rosendale cements: polymer cement mortar: Hime mortar: Pozzolana mortar, and the like, as well as mixtures theroot. [0075] Exemplary pozzolanic andor burned organi mat- ter residues may inchade, but are not limited to, limestone: Aly ash (eg. siliceous ly ash andor ealeareous ly ash), for ‘example Class C fly ash, Class Fly ash, pulverized iy ash liafine Class F fly ash slags ground blast furnace slag (GGBPS or GGBS); cement kiln dust (CKD); silica fume or other fine forms of silica sochas fine silica ou: metakolin: vitreous calcium aluminosilicate (VCAS) carbon nanofibers And ether earbon previnets; calcium hydroxide (Ca(OH): ‘ate palm ash or simply “palm ash”, which is produced as ‘wastage during the production of palm firewood and coal products (typically has a chemical constitution of 30-40 vt. %6 SiO, O.1-10 Wt. % of FesOy, 10-15 wt. % of CaO, 0.1-1,0 Wt % of ALO, 5-10 wi. % of MgO, 2-10 wt % of K.O, and 1-5 wi. % Of Na,O}: bumed palm oil products (Ger than palm cil fel ash) such as oi palm shell (OPS) rice husk ash; voleanic ashes and pumiees (eg. crushed voleanie glass); diatomaceous earth; symthetie pozzolans such as synthesized reactive aluminosilicate glasses; zeolite ‘materials such as calcined zeolites; cenospheres; pozzolan calcined shale; trass; pumice: siliceous clays: metropolitan waste ash; sewerage ash; coal Wash tailings: mineral a ings; scoria; obsidian; other fue ashes; and other ash derived ‘rom buming omzanie waste, Ageregte [0076] The concrete composition ofthe present disclosure includes one or more coarse aggregates. Coarse aggregates fare used 0 influence the conerete’sfieshly’ mixed and hardened propesties, mixture proportions, axl economy of producing, The types and amounts of coarse aggregate can be varied depending on the application. For example, the type and amount of coarse aggregate can be varied t0 produce a lightweight conerete with a bulk density com- ‘monly less than about 1450 kg/m, anormal weight conerote ‘with bulk density of about 1500 to 2400 kwim? (ASTM 33), or a heavyweight concrete with a bulk density of areater than 2400 kyl’ (ASTM C637 and C638), [0077] Exemplary coarse aggregates include, but are not limited w, crashed roeycled conerete, crushed stone, gravel, socks, natural sol, quarried enushed mineral agarepates from jgnonus (granite, syenite,diorite,gabbro perdotite pegma- tie, voleanie glass, felsite, basal), metamorphic (earble, rmetaguartzite, slate, phyllite, schist, amphibalite, horfels, ness, serpentite) oF sedimentary. rocks (conglomerate, sandstone, claysione, siltstone, arilite, shale, limestone, dolomite, marl, chk, cher), including unused and waste aggregates from quarry oporations, dredged. ageregates, china clay stent, china clay waste, natural stone, recycled bituminous pavements, recycled concrete paveriens, reclaimed road base andl subbase materials, enished bricks, cconstniction and demolition wastes, wasteiecycled flue gas ashes, crushed glass slate waste, waste pasties, egg shells,US 2021/0039997 AI sea shells, barite,Iimonite, magnetite, ilmenite, hematite, iron, sec, including rocycled of scrap stel, and mixtures thereot. In preferred embodiments, the evarse aggregate is ‘enshed stone. 10078] The amount of coarse augreyate deployed herein may vary, but typical values range between but typical valtes range between 12 %0 33 wT. preferably 14 1031 wt %, preferably 16 to 30 wt. %, preferably 18 10 29 wt. %, preferably 20 to 28 wt. 96, prelerably 22 10 27 wt. °%, preferably 24 to 26 wt. %, based on a total weight of the ‘conerete composition. 10079} Typically, the coarse sgareyste has particle sizeof 2 vo 20 mm, preferably 2.1 wo 18 mm, preferably 2.3 to 16 ‘am, prelerably 25 10 14 mm, preferably 3 to 12 mm, preferably 4 10 10 mm, preferably $c 8 mm, although ‘course aggregates with particle sizes above or slightly below these values may also function as intended, The grading of ‘course aggregate employed herein preferably conforms t0 the standard ASTM C3NC33M-I8, which is incorporated herein by reference in its entirety. [0080] In preferred embodiments, the coarse aggregate Utilized in the eonerew composition has 2 bimodal particle size distribution, preferably» bimodal particle size distribution with a first mode particle size of 4 to 12.5 mm, preferably 4.25 to 10mm. preferably 4.5 o 8 mm, preferably 4.75 to 6 mm, and second mode paniele size of 2to less than 4mm, preferably 21 10 3.5 mm, preferably 22 w 3 mm, preferably 2.3 10 2.8 mm, preferably 236 to 2.6 mm. In ome embodiments the first mode particle size isthe pre- ‘dominant partiele size, In some embtiments, a weight ratio ‘of the first mode particle size to the second mode particle Size is from 1:1 10 5:1, profeably 1-2:1 to 45:1, peeferably 14:1 to: proerably 1.6:1 35:1, preferably 18:1 03:1, preferably 2:1 © 25:1 [0081] In prefered embodiments the coarse aggregate has a saturated surface dry (SSD) specific gravity of 2.4 to 2.7 preferably 2.45 to 2.65, preferably 2.50 2.6, preferably 2.33 to 2.6, Saturated surface dry (SSD) is ‘defined as the ‘condition of an aggregate in which the surfaces of the Particles are “dry” (.e, surface adsorption would no longer take place) but the interparticle voids are saturated with ‘water In this condition aggregates will not affect the free ‘water content of a composite material. That is, SSD specific nivity is the ratio ofthe weight in ar of a unit volume of ‘aggrezate, including the weight of water within the voids filled to the extent achieved by submerging in water for ‘approximately 15 hours, and where the excess, free surface miisture has been removed so that he surface of the particle js essentially dry, to the weight in air of an equal volume of gas-five distilled water at the sated temperature, for ‘example, according to AASHTO T 84. 10082] ‘The concrete composition ofthe present disclosure also includes one or more fine agaregates, The fine aggre- ate may include, but is not limited to, sand (eg., dane Sand), of any of the materials listed for coarse aggregate Which lave been ground pulverized int fine particles. la the ‘event a coarse aggregate and fine aggregate are used in the ‘concrete composition that s sourced from the same materia, for example, crushed limestone, then the panicle size will lictato whether itis defined as coarse of fine aggregate. In preferred embodiments the fine aggregate employed herein js dune sand. The fine aggregate may have an average panicle sizeof 03 to less than ? mm, preferably 035 to 1S ‘mm, preferably 04 to 1.0 mm, preferably 0.45 w 0.9 mm, Feb. 11, 2021 preferably 0.5 (00:8 mum, preferably 0600.7 mm, although fine aggregates with average particle sizes slightly above oF below these values may also function as intended. The arading of fine aggregate employes herein preferably on- forms to the standard ASTM C 33/C33M-I8, which is ‘incorporated lerein by reference in its entirety [083] ‘The amount of fine aggregate deployed herein may vary, but typical values range between but typical values range between 8 to 30 wt % preferably 9 10 27 wt. %, prefembly 10 to 25 wt. %, preferably 11 to 28 wt. % preferably 12 10 20 wt. %, prelerably 13 10 18 wt. %, preferably 14 t0 16 wt. %, based on total weight of the toncrete composition. [84] In prefered embodiments, the fine aguregate bas @ fineness modulus of 1.8 to 2.1, preferably 1.81 to 20, preferably 1.82 to 1.9, preferably 183 to 1.88, preferably 1.84 fo 1.86, preferably 1.85. The Fineness modulus (FM) is fan empirically determined index of the fineness of an ‘agereyate—the higher the FM, the coarser the aggregate ‘The fineness modulus is obtained by adding the cumulative percentages by mass retained on cach ofa specified series of eves and dividing the sum by 100, The specified sieves for {termining the fineness modulus for fine aggregate are 0.15 ‘im 0.3 mm, 0.6 mam, 1.18 im, 2.36 mm, 4.75 mn, and 9.5 ‘im, for example, according to ASTM C125 and ASTM C3RICSEM-IS, [0085] In prefered embodiments, the fine aggregate ss saturated surface dry (SSD) specific gravity of 25 10 27, preferably 2.55 to 2.68, preferably 2.6 to 2.66, proferably 261 to 2.64, preferably 2.62. [0086] In some embodiments, « weight rato ofthe coarse Aagaregate to the fine agaregate i 1:1 10 2:1, preferably 1.1:1 to LS:L, preferably 12:1 to 13:1. That is, preferably, the coarse agareyate accounts for $0 10 66 wt % of the total agaregate (coarse plus fine aggregate), preferably 52 t0 60 ‘wt %, proferably 54 10 56 wt. %, preferably 35 91. %, [0087] The amount of total aggregate (TA) utilized herein ‘may vary, but typically « weight ratio of the total aggregate (coarse plus fine ageregate) to the treated palm oil el ash ranges from I:1 to 2:1, preferably 1.21 to 195:1, preferably 14:1 10 19:1, preferably 1.6: 10 1.85: preferably 17:1 0 18:1. In some embodiments, the total aggregate has a fineness modulus of 3.0 10 4.2, preferably 3.2 0 4.1, preferably 33 to 40 preferably 3.410 39, preferably 3.5 10 38, preferably 36 10 3.7 Alkali Activator [0088] An alkali activator must be included inthe concrete ‘composition. Alkali activation generally releases reactive species (e3., CaO) Irom the binder, thus increasing the rate of densification and improving the microstructural streagth of the binder, which by extension affets the mechanical properties and durability performance ofthe cured concrete ‘The alkali activator may be a mixture of an aquenus solution ‘ofa metal hydroxide, preferably an alkali metal hydroxide (ea. sodinm hydroxide, potassium hydroxide, etc), and a peta silicate, preferably an alkali metal silicate (e., sodium silicate, potassium silicate, le). In some embodi- ‘ments, the alkali aetivator may be an aqueous solution of & metal hydroxide, preferably an alkali metal hydroxide [0089] "In prefered embodiments, the alkali aetivator is an ‘aqueous mixture of sodium hydroxide and sodium silicate Preferably, the alkali etvator consists of sodium hyedrowide ‘and sodium silicate in water A weight ratio of sodiUS 2021/0039997 AI ay wenerally range from 1:1 1, preferably 1.41 to preferably 1.6: t© 27:1, preferably 1:81 t0 2.6:1, prefer ably 2:1 to 25:1 In some embodiments, dhe sodium slieate has a silica modulus (Si0..Na,O weight ratio) of 15 0 4, preferably 210 3.8, preferably 2.510 3.6, preferably 3 to 3.4 preferably 33. In some embeadimens, the som hydroxide has @ specific gravity of 2 to 2.4, prefembly 205 to 2.3, preferably 2.1 to 2.2, preferably 2.13, 0090] In preferred embodiments, the eonerste composi tions are prepared using a weight ratio ofthe alkali activator to the treated palm oil fel ash of from 03:1 to 07:1 preferably 0.34:1 to 65:1, preferably 036:1 to 06:1, preferably 0.38: to 05-1, preferahy 0.4:1 to 05:1 [0091] The Way in whieh the alkali activator i prepared may also impact the final properties ofthe cured conerete. For example, the concentration of the sodium hydroxide used to prepare the alka aetivator has heen found! o impact the compressive strength of the cured concrete. Typically, the sodium hydroxide and sodium silicate are premixed in the form of an aqueous solution, and this aqueous alkali activator solution is then added to any dry components 10 Tom the concrete composition, at will be discussed here- inate. In this process, it has beon found that use of an ‘aqueous solution of sodium hydroxide having a concent tion of & to 14 moll, preferably 9 to 13 mol, preferably 10 to 12 moVL, preferably 10 moVL ultimately provides ‘cured coneretes with superior compressive strengis properties, Without being bound by theory, itis believe thst sue molar concentrations of sodium hydroxide combines with the sodium silicate in such away that eflecs the rate of silica nd alumina release from the palm ol fuel ash material, and the enhanced dissolution produces cured concrete with supe- Flor strength characteristics (eg, compressive strength) Water 10092} ‘The cement composition also includes water. In ome embodiments, the weight ratio of the water to the tweated palm oil fue ash is 0.06 1 0.98, preferably 0.110 0.9, preferably 0.2 (0 0.8, preferably 0:3 to 0.7, preferably 0.40 1045, preferably 0.5 to 055. In prefered embodiments, the ‘conerote composition contains 2 to 15 Wt %, preferably 310 14 wt %, prelembly 4 to 13 wt. %, preferably $10 12 wt 9%, preferably 6 to LI wt, %, preferably 7 to 10 wt. %, preferably 8 to 9 wt. % water, based on foal weight ofthe ‘conerete composition, However, such ritios and percentages fare exemplary of typical values, and a penon of ordin ‘ill ean adjust the water content ofthe coneree com tions as needed to suit the application or workability require ‘ments, and the water to binder (POF) weight ratio or water ‘weight percentages may therefore Tall outside of these described ranges. Suitable water sources include fresh Water, Potable water, andthe lke, preferably potable water Additives 10093] In some embodiments, the concrete compositions “only nee neo mow aves such as seat ‘enhancer, an accelerator, a retarder, a plasticizer (© superlasticize) a pigment, coroson inhibitor, a bonding lagen, and a reinforcing material including mixtures thersot The additional additives), when present, may be present in an amount up t § wt. %, preferably up to 4 wi. %, preferably upto 3.9%, preferably up to 2 wt. %, preferably up to 1 Feb. 11, 2021 wt %, preferably up v0 05 wt. 2%, preferably up 1 0.1 wt %, preferably up o 0.05 wt. a, preferably up to 0.01 wi. % based on the tolal weight of the conerete composition. 094] ‘Tae concrete composition of the present disclosure ‘may optionally include a siength enhance, preferably an sluminum-contsining strength enhancer. Exemplary Strength enhancers include, but are not limited to, aluminum Sydonle ((0Hp, sodium dod: potisium Mooi, im sulfate, sodium oxalate, an alkali phosphate (©. ‘Stun pps) and ced compos to ae few. In Some embodiments, when employed, a weight ratio of the strength eahaacer to the treated pal oil fuel ash is 01:1 10 0.05:1, preferably 0015:1 to 0.041, preferably 0.016:1 to 0.03:1, preferably 0.018:1 to. 0025:1, preferably 0021 [095] An accelerator is any chemical eapable of eceler= ating the hardening (cary strength development) of con cree. Suitable examples of accelerators that may be included in the concrete compositions herein include, but are ‘ot limited to, caleium nitrite, calcium nitrate, ealcinm formate, caleium chloride, sodium nitrate, or a combination thereat: [0096] A rearder i any chemical capable of retarding the ‘hardening (early stengrh development) of concrete, Acsept- able examples of retarders include, but are not Iimited 0, a borate salt sueh as of sodium pentaborate (NasB 0), sodium tetraborate (Na,B,0,) and boric acid (HBO, ); 0 ‘organophiosphonate such 3s" sodium or calcium salts of ethylenediaminetetra (methylenephosphionic acid) (EDIMP), hexamethylenediaminetetra(methylenephosphe- nic acid), and diethylenetiaminepenta (methylenephospho- nie acid); serylamide copolymers such as copolymers formed. from 2-aerylamido-2-methylpropane-3-sulphor acid (AMPS) and one or more acrylic ace or non-sulfonated ‘serylamide mononiers; metal sulfates such as ferrous stl- fnte; gypsum; sugar, sucrose; sodium gluconate: glucose: citric acid tartaric acid; and the Hike; as well a mixtures thereo: [0097] Broadly, a plasticizer isa material that when added to another yields a mixture which is easier to handle or as areater uty. The plasticizer as used herein means an ‘onganie compound which is usually non-volatile at standard oom temperature and pressure (25° C,, 1 atm.) and whieh bas no specific chemical reactivity, As sch, the plasticizer is generally inert towards the binder and merely serves as 9 :medium in which that binder may be suspended or otherwise isporsed. Suitable plasticizers may inchide, but are not limited to, polyalkyleneglycols and other polyethers suc as polyethylene glycol, polypropylene alyeol, and polybutyle- ‘eglycol, including blends of ovo oF more of such polyalkyleneglycols or blends of one or more of such polyalkyle- reglycols with one or more co-plasticizers, as well as phosphonic acid terminated —polyalkylene glycols: sulfonated or phosphorylated organic compounds sch as alkyl sulfone aeid esters of phenol and ereso (for example MESAMOLL trom Lauxess) and aromatic sulfonamides: alkyl or aryl esters of omganic acids such as benzoie acid esters of glycols and their oligomers, esters of 1,2-dicar boxyeyelohexane (hydrogenated phihalaes), phthalic acid esters, terephthalic acid esters, timellitaes, adipic acid testers, sebasie acid esters, tartrate esters, citric acid esters and sterose esters; oils Which can be natural or symhetc stich as vegctable oils and their derivatives including fatty acid esters and epoxidized vegetable ols, onzanie liquidsUS 2021/0039997 AI derived from wood and other forest produets like liquid rosin stem, hydrocarbon fluids such as mineral oil or paralinie liquids, and silicones: vinyl polymers such as polyisobutene Liguid polybutadiene, and polyearboxylates such as poyearboxylate ethers (PCF) made from polymers ‘of aerylic acid andr maleie acid with ether side chains, for ‘example FTHACRYL proves from Arkema or MASTER- ‘GLENIUM products fom BASF: polyesters; formaldehyde (formalin) resins (condensates) suchas sulfonated naphiha- lene formaldehyde resin, sulfonated melamine formaldehyde resin, acetone formaldehyde resin, e., crosslinked PMS (polymelamine sulfonate) and croslinked -PNS (polynapithatene sulfonate): and mixtures thereof. [0098] One particular type of plasticizer known as Superplstcizer (SP) may be optionally employed in the disclosed concrete compositions. Supemplasticizers are also Known as high range Water reducers, and are aditives generally used in making high stength mortar or concrete In prefered embodiments, when present, the superplstcizer satisfies the ASTM C494/C494M-17 requirements, whichis incorporated herein by relerence in its entirety. The superplstcizers that may be employe in the present disclosure include, but are not limited to, polyalkslary sulfonate superpastcizers, such as condensation procts of naphthalene sulfonic acid with formalin ora salt thereof, a ‘condensation product of methylsaphthalene sulfonic acid with formalin ora salt thereof, and a condensation product ‘of anthracene sulfonic acid with formalin ora salt thereof for example, MIGHTY 100, MIGHTY 150, and MIGHTY 200 each available from KAO Corporation, and PANTAR- HITT FE-500 available from Ha-Be Betonciemie; melamine! formalin. resin sulfonate supemlasticizers, for example MELMENT F-10 available from BASF; sulfonated copoly- mer superplastcizers such as. syrenc-c-methystyrene ‘copolymers containing # mole ratio of from 90-10 to 10:30, preferably 30:70 to 70:30 of styrene to amethslstyrene polyearboxylates, in particular polyearboxyate ethers such those made from eopolymeriztion of (methacrylic weds maleic andride, maleic acids or ther salts, with polyoxy- ‘ethylene (methacrylic esters or adducts of polyethylene ‘derivatives to vinyl monomers, for example MELFLUX or MASTERGLENIUM product vailale from BASF: orany ‘other plasticizers exhibiting stong tackiness and non-bleed ing properties: including mixtures there: In some embodic ment, when present, the sopemplasicizer isa chlorde-ree superplastcizer. In prefered embodiments, when presea the superplstcizeris a sulfonated naphthalene formalin 10099] Pigments may’ be optionally included in the eon- ‘rete composition to eventually form colored cured con- ‘ereies. Exemplary pigments include, but are not limited o, iton oxide, natural burt ume, carbon black, chromium ‘oxide, ulirosmarine blue, titanium dioxide, among many ‘other pigments known to those of ordinary skill nthe arto provide coneretes with desirable coors [0100] ‘The concrete compositions may optionally be for mulated with comosion inhibitors. Any eorrosion inhibitor Known t0 those of ordinary skill in the art for use in rmortariconerete applications may be used herein, with spe- sifie mention being made to nitites (ea ealeium nitrite), ‘chromates, phosphates, benzotrizoles,alkanolamines e-8 NuN-icthyl-cthanolamine, N-methylethanolamine, mono- hanloamine, dicthanloamine, trethanloamine), including mixtures thereat Feb. 11, 2021 [0101] Bonding agents may also be optionally included the concrete compositions. Exemplary bonding agent include, but are not ited to, luau sulfate, latex esis sueh as acrylie polymer latex resins, epoxy resins, vinyl polymer resins, and mixtures thereof [0102] ‘The conerete composition may also optionally be Tormulate to include at least one reinforcing material, The reinforcing materials may provide increased strength and impact resistance by increasing the Mexural and tensile strength of the cured eonerete formed fom the concrete composition and thus increasing. the amount of energy eqired to cause rupture and complete failure. Exemplary reinforcing materials include, but are not limited to, steel rebar, wire mesh, stecl fibers, and synthetic polymer fibers suel as polypropylene fibers, nylon fibers, and polyvinyl allio! (PVA) ess. [0103] In some embodiments, the conerete composition is substantially free of additives. In some embodiments, the concrete composition is substantially five of steagth enhancers (e., aluminum hydroxide). In some embodi- meats, the concrete composition is substantially free of plasticizer, in particular, superpastcizers. In some embodi- fenls, the concrete composition is substantially [ree of ‘organosilieon compounds. In some embodiment, the eon- crete compositions are substantially Fee of syathetic poly ‘mers sch as polyvinyl alechol (PVA), including PVA Bers, either coated or tseaated. In some embodiment, the con: ‘rete composition is substantially free of foaming agents. In some embodiments, the conerete composition is substantially free of defoamers. In preferred embodiments, the concrete composition coasists of the treated palm oi fuel ash, the coarse aggregate, the fine aggregate, sodium hhydeoxide, sodium silicate, and water [0104] In some embodiments, the concrete composition hs a Workable flow, expressed as a percentage increase in the average base diameter of «50 mim cube concrete specimen aller performing table drops compared 10 the original base diameter, of 105 w 140%, preferably 110 t0 135%, preferably 115 o 130%, preferably 120 0 125%, per ASTM C1433, which is incorporated herein by reference in its entire, [0105] Any method known by those of onary skil in the fart may be Used fo make the concrete composition of the present disclosure. One exemplary method will now be briefly deseribed, [0106] The concrete compositions of the present disclosure may be prepared by first dry-mixing the binder (e.. treated palm oil fuel ash), the fine aggreyate, and any solid ‘optional additives either by hand or using a mechanical ine such as a Hobaet planetary bench mixer for any period suitable for removing air pockets and forming a ‘uniform mixture of dry materials (dey mix) Typical mixing times may be around 0.5 to 10 minutes, preferably 1 to S minutes, preferably 2 0 3 minutes. In some embodiments, such a dry mix may be obtained as @ preformed andlor sre-packaged dy mix. The course aggregate may be added long withthe other components that make up the dry mix ‘or may be combined with an already formed dry mix, and evenly distibuted throughout [0107] Nex, the alkali aetivator (e.gan aqueous mitre ‘of sodium hydroxide and sodium silicate) may be added and the mixture may be mixed for Ito 10 minutes, preferably 3 to 8 minutes, preferably $ to 6 minutes, although time periods outside of these ranges may also be acceptableUS 2021/0039997 AI 10108] In some embodiments, all of the water used 1 make the concrete composition comes from the ation of the alkali activator. Alernatvely, in some instanoes it may be desirable o add additional water and/or any optional aditive(s) (eg. supeeplasticizer) afer alkali activation to Improve the consistency/orkable flow of the concrete ‘composition or to otherwise change the properties of the ‘concrete compositionlcured concrete. When additonal ‘water and/or optional aditive() are added the mixture may be preferably mixed for an additional 1 to 10 minutes, preferably 3 10 8 minutes, preferably 4 to $ minutes, oF blherise to provide an overll average mixing tiie of 810 16 minutes, preferably 10 to 14 minutes, preferably. 12 minutes. Invermitently, the mixing operation may be stopped to remove any clumps of solid materials that stick to the botiom of the mixing vessel, and then mixing may be gain continved until a desirable homogeneity and consistency of the concrete composition has been achieved 10109] Of course, the relative amounts ofthe components may be adjusted at any point to achieve concrete composi tions having the desired properties. For example, the work= able flow may be tested according wo ASTM C1437 and the relative amounts of any components) (eg. water, coarse ‘aggrepate, fne aggregate, binder, andlor any optional add tive(s)) may be adjusted as needed to be within desired specications ‘Cured Concrete [0110] After forming the concrete composition, the con- ‘rete composition may be molded (and demolded), casted, placed, applied, compacted, and/or finished, and cured (st) 8s needed to suit « particular application. For example, the ‘concrete composition may be fed into-a mold, demolded and ‘cure, 1 ereate any desied shape, for example the shape of ‘4 masonry block for application in construction materials ‘The concrete composition may be eatin # mold offsite and ‘cured to produce a precast o the concrete compositions may be cast in a mold or into a site-specific form onsite and ‘cured. The concrete composition may be molded, casted, placed, applied, and then optionally vibrated ina filled mold ‘or site-specific form to remove air andior minimize sogre= gation. In some embodiments, a top surface of the filled ‘mold is removed and fresh mixtore is added 0 fill he mele. Sach vibration andior filling steps may be repeated as nocestay to produce the desired composition oF product. Any molding. casting. placing, applying, compacting, fine ishing, andor curing steps may be carried out ina ontolled ‘environment offsite, for example when forming a precast, ‘or perfoemed on site in standaed conerete processes [O11] Curing may be carried out under ambient cond tions, for example 20 to 35° C., preferably 23 to 30° C preferably 25 1 28° Cor through applied heat, for example ft temperatures of 50 to 70° C., preferably $5 to 65° C. preferably 60° C. The cure times may vary from 1 day to 180 days, for example, 13,7, 14,28, 90, 180 days and any time Jn beeween those sated values, preferably 7 to 28 days. 10112] In some embodiments, dhe cured concrete has 2 unit ‘weight of 2200 to 2300 ky/m’, preferably 2210 to 2250 wim’, preferably 2220 to 2280 Kw/m, preferably 2230 10 2270 Kgl", preferably 2240 vo 2260 kyl" preferably 2250 kein’ [0113] The concrete composition deseribed herein provides cured concrete with high compressive strength espe- cally considering that cement is preferably Fully replaced Feb. 11, 2021 with a waste product (ie, treated palm oil fuel ash). The ‘concrete composition provides, aller curng/setting. «cured concrete with a 28-day compressive strength of 33 10 49 MPa, preferably 34 to 48.5 MPa, preferably 38 10 48 MPa, preferably 36 to 47.5 MPa, preferably 37 to 47 MPa, preferably 38 to 46.5 MPu, preferably 39 to 46 MPa preferably 40 10 45.5 MPa, preferably 41 to 45 MPa, All compressive strength tests may be tested using S0-mm concrete samples according 1o ASTM C39, whieh is incor ported herein by reference in its carey. [0114] The disclosed concrete compositions may be useful in many stevetoral and infrastructural applications that uti- lize eonerct, brick, or other structural element as building ‘material, and in the manufacture of various end use articles ‘or products. In some embodiments, various cured concrete products are formed from seting/euring the dselosed concrete compositions. The disclosed cured concrete products may be inthe form of useful shape, formed by 3 variety of ‘means such as, for example, using mols, casts, or forms, oF the like, in accord with their intonded use, Any typical process of forming conerete can be sel here, Thereore, the cured conerete may refer toa molded aniele o building ‘material. Por example, the cured concrete may be applied 10 ‘or otherwise used to form, slabs, panels, precast panels, wall boards, hollow blocks, floor aad roof tle, cateh bas ‘manholes, beams, columns, posts, conduits and pipes, grave- stones, insulators, external cladding, slate, concrete decking. eg. swimming pools, surfaces and surmounds, coramic style products, marhle like prodts sink tops, bar tops, bathroom tops, table tops, fireplace tiles, fire proof walls, building blocks (eg masonry blocks); both reinforeed and not rein- {oreed by tee, depending on the use and purpose for which the manufactured products are fabricated. In some embod ‘ments, te cured conerete described herein possess sufiient ‘mechanical properties for use in applications described ia ASTM C138, which is incorporated horein by reference in its entiroy [0115] The cured concrete may be optionally reinforced as ‘needed depending on the application, There are various ways of making reinforced concrete, Reinforced concrete can be made by forming the conerete inside & metal or timber ramework or by casting the conerete composition around ridged stcel bars, or rebars (reinforcing bars) and ‘then cured, Another variation called sessed or pre-stessed ‘concrete involves molding the conerete composition (Wet) ‘round pre-fensioned steel sires, The wires compress the ‘concrete a8 it sets, making it much harder. [0116] Having generally described this disclosure, a further understanding ean be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be Kimiting unless otherwise specified [0117] Where « aomerical limit oF range is stated herein, the endpoints are inchided. Also all vales and subranges ‘within a numerical limit or range are specifically included as if explicitly writen ost [0118] The present disclosure also contemplates other ‘embodiments “comprising”, “consisting of” and “eonsisting essentially of", the embodiments or elements presented herein, whether explicitly set forth oF not [0119] As used herein, the words “a and catry the meaning of “one or more.” [0120] Obviously, numerous modifications and variations ‘of the present invention are possible in light of the above 1d the lkeUS 2021/0039997 AI 10 teachings. It is therefore to be understood that, within the scope ofthe appended claims, the invention may be pric- iced otherwise than as specifically deseribed herein. [0121] All patents and other references mentioned above are incorporated in full herein by this reference, the same as if set forth at length, EXAMPLES Materials and Methods Palm Oil Fuel Ash (PORA) 10122] POFA was the only aluminosilicate source material rid was obtained fom United Paim Oil Mill Sdn. Bh. in Nibong Tebal, Penang, Malaysia, Iisa by-product from the ‘combustion of empty palm frit bunches, pal Keene shells ‘and fibers; nomally used to heat the boiler for electrical ‘energy generation in the palm oil mill FIG. 1 shows a ‘ypical dumping sive for raw POA, which is a combination ‘of well-bumnt ashes and partially’ burat polis shells and ‘bers. The raw POFA particles are predominantly dark in ‘color due to the presence of high earbon amounts from incomplete burning of tho residue, To adequately harness the inherent benefits of POFA, POFA was treated to remove ‘unwanted residue following the procedure highlighted in FIG. 2. This was achieved by deying the eatvely moist aw POFA in an oven at 10028 ° C. for 24 hours, as shown in FIG, 310 remove the moisture and to allow for exse of particles movement through the sieves. After drying, the {ried POFA was sieved through a set of sieves (600 um and 300 jum) t remove coarser and unwanted materials, Subse- ‘quently, afer sieving, the sieved POPA was ground by a ‘mechanical bell mill.‘The mechanical ball mill shown ia FIG. 4 has an approximately 7 kg-contolled capacity for ‘each eyele to achieve an eficient grinding of OPA. Itholds 150 steel balls of sizes ranging from 6 mum fo 32 mm and rotating at speed of 180 pm. Grinding was done to decrease the particle size of POPA aad to increase is sure arco, ‘which ultimately led to improved pozzolanie reactivity. At this stage, the POFA material is physically processed but not thermally treated, hence refered to as ground POFA (GPOFA), To remove unburat carbon, prevent glassy’ pase ‘eystllization and agglomeration of particles, the ground POFA was heated at 550° C. ina gas-powered furnace for 90 min, Aer this ealeination process, shee isa change in color Jom black (ground POFA, FIG, 8) to prey (calcined POFA, FIG. 6) due to the romoval of earbon responsible for the black color. To further improve the surface area and specific _anvity the caleined POP is ground for another round inthe ball mill to provide treated palm oil fuel ash (TPOFA). This case the particles characterized by low specific gnvity have had improved fineness and particle size, hence increased specific grivty. The POFA treatment procedure adopted was due to the highest improvement achieved, Which was measured by the least amount of unburat carbon ‘content. The synthesis of alkali activation of POFA material ‘vill improve heeause of the carbon content reduction. The Joss on ignition (LOI) values reduced from 26% to 23% aller beat treatment, a sign of low unburned residue in the POFA-The reduction in the LOl vale is compensated for by an increase in the mass percentages of other oxides. 10123] The particle size distribution of the final stage of preparation of POFA was determined using Laser Particle Sizer Analysette 22 MieroTee plus particle size analyzer Feb. 11, 2021 (PSA). The value ofthe surface area was detemnined using ‘Micromerites ASAP2020 BET using nitrogen gas adsorption, Table 1 shows the oxide compositions and physical properties of TPOFA and GPOFA, which were determined using X-ray Nuorescence (XRF) technigne. Wit otal oxides of silicon, aluminium and iron of 79.07%, the TPOPA ‘complies withthe specification of ASTM CE as lass Fly ash (ASTM C618, 2012). TABLE 1 Sevres Dl wenn 7 Phosioms san an Seep oO Alkaline Activators [0124] A mixed solution of NaOH.) and Na,SiO, was used as an activator in the developed kai-aetivated eon- crete (AC). Sodium hydroxide is cheap material and its ‘widely available, making ita choice activator inthe alkaline sctivation of the precursor material, in this ease POFA. However, the cormsive nate af the highly alkaline alk hydroxides presents handling issues. Commercial prade sodium hydroxide pellets with 97% purity and. specific arity of 2.13 were used in the preparation of sodinm hydroxide solution. The NaOH, solution Was prepared by issolving either the Makes or pellets in water. The mass of NaOIT solids (flakes or pellets or in a solution) varied ‘depending. on the concentration of the solution expressed in terms of desired molarity ofthe solution. For example, 8M [NaOH solution was prepared by dissolving 319.976 of [NaOH (in fake or pellet Form) in one liter of distilled water [0125] Sodium silicate (Na,SiO,), also known as water lass, was also used in combination sith NaOH as an alkali Activator. The silica modulus (SiO, to-Na,0 (or K,0) ratio) varies from 1.5 10 4, The hydrates of Na,Si0, have the formula Na,SiO,.nH1,0 where n-S, 6, 8, or 9. Available water glass has @ silica mosis of 3.3 and holds 36-38% solidsUS 2021/0039997 AI W Water 10126] Potable water, whose physiochemical composition show in Tuble 2, was used inthe developed akali-aetivated cconerote (AAC) ABLE 2 ‘Psiucnicl ais pole anus __ Anite! Meiod Late” Re ator Seon sereu are meme emi thd) = = sue Been 20 mel Lead Bit hae ot met. <0007 at. ‘i rie gown OS Aggregate [0127] In the design ofan alkal-aetivated concrete, selection of agaregaes is important as most of the matrix volume js oceupied by aggregates. The gradation of coarse and fine aaregate (CA and FA) is in accordance withthe provisions ‘of ASTM C33/C33M-18 (2018), The FA was dune sand with fineness modulus of 1.85 while total aggregate (TA) had a fineness modulus of 3.66. The FAVTA ratio was 0.45 while the specific gravities ofthe CAA and FA inthe saturated and surface dey (SSD) conditions were 2.55 and 2.62, respectively. 10128) The coarse aggregate (CA) used for the AAC was ‘rushed stones composed of sizes 4.75 mm and 236 mm, Which according to ASTM C33 are size No. 4 and No. 8 respectively: The ratio between the size No, 4 and No. 8 used was 2 Superplasticizer [0129] A commercially available polycarboxylie ether basedsupesplastcizer (SP), MASTERGLENIUM 5, available from BASF sacsiying the ASTM C494/C494M-17, (2017) was used to modify the workability and to achieve adequate theological properties of the developed alkali fctvated conerct, It is @ chloride-free super plasticizing ‘admixture, Mixture Proportoning [0130] AAC with composition shown in Table 3 was prepared with 100% TPOFA, as the binder, with varying ‘coarse aggregate to total aggregate ratios (CAVTA) and fine aggregate to total aggregate ratios (FAVTA) and constant TAPOPA ratio of 18. The alkaline sctivators used were prepared from a mixture of NAOH(,,) (NH) and Na,SiO (NS) sith activator’ lative proportion —(Na,SiO,, NaQHep} [X-10, 12 and 14M) whose ratios were’3'5, 2 Feb. 11, 2021 and 1, respectively. The NaOH pellets were measured before ‘issolution and placed ina beaker depending on the required molarity; distilled water was then added and thoroughly mixed. For instance, 10M NaOH, is prepared by mea- suring 399.97 g of NaOH pellets into beaker and distilled water added to the 1000 ml mark on the beaker, The solution, which is exothermic, is sted until all the pellets hhave dissolved and a clear solution is obtained. After preparation, the solution is allowed to coo! dawn to prevent the alkaline setvation process from thermal interference from the exothermic NaOH.) solution. Based on the alkali activator ratio, the Na,Si0, Solution was added to the veasured NaOH,,,, solution and thea mixed for several TABLE 3 ‘Cotes oft dscned AAG ss «xa he ease os 03s Se ™? 2 os Oss 586. Mt os O88 108 Mo os 05s 106 sao as oss Se Ma 0351085 MB 2 03s Se sas os oss a Nas oe 03s ae sar os 03s 108 Ni ae 03s Se Soo oe 03s oe sat ae 03s Se Concrete Mixing Procedure [0131] An approximate unit weight of between 2200-2300 kgim? for the POEA alkali activated concrete is quite com- parable to that of typical Portland cement conerete. In the preparation forthe POFA alkal-activated conerete matrix, POFA and aggregates (line and coarse aggregates) were ixed thoroughly in dry condition using a Hobart planetary ‘bench mixer model NSO-60 to get uniform mixture of dry materials. Subsequently, the alkaline activators (a mixture of Na,SiO, jy and NaOH...) were added othe dry materials ‘mixed for’ mins and then followed by the addition of water andor superplasticizer (SP), after which mixing was con- ‘tinued for another 4-5 mins. Intermittent, the mixer was stopped to serap manualy the solid materials sticking to the bottom ofthe bowl. The mixing continued and stopped when homogeneity and consistency of the cancrete mixture have been reached after 1-2 minutes,US 2021/0039997 AI 12 Casts 10132] Different specimen specifications and dimensions ‘were used fo test the specimens for compressive, tensile, and ‘lexural strength. For the compressive strength, the mixtures were east in two layers into SO max$0 max30 mam oil smeared steel molds. Each layer was compocted on a vibral- ing table for 1-2 mins after which the fresh POFA alkali: activated conerete (POFA-enginccred cementitious composite (EACC)) samples were covered in vinyl bags to prevent ‘moisture loss and let in the labortory at 25°C for 24 hors prior to demokling. The specimens were demolied and placed in vinyl plastic bags prior to curing in an oven at 6085°C. for 24 h, This was to aid i the alkaline aetivaton reaction for early strength increase. After the eat curing. dhe hardened samples were subsequently allowed to evo! down Jn the laboratory until predetermined ages forthe test. The same procedures were adopted to evaluate tensile and lex- tal drength specimens. and Curing of Concrete Speci ‘Test Methods (0133) The optimiza POA alaivainted eonerte ns were prepared and evaluated to determine the Blowing properties acconling to sandard procedures at appropriate curing periods 0134] i) In accordance with ASTM C1437, the fresh properties (Workable flow) of the PORA alkali-act: ‘ated conerete Was detennined using a ov table test ‘on 50 mim cube specimens ofthe POFA alkal-acivated Feb. 11, 2021 [0135] i) nsccordance to ASTM C39, the compressive strength of $0 mm POFA allali-activated eonerete cube specimens alter 7 and 28 days of euring was messured Results and Diseussion Frosh Peopertos of POA Alkali-Actvated! Concrete [0136] The fresh properties of the POFA alkali-activated fsoncrete was determined in order to study the elfets of ‘water and the commercial superplasticizer (SP) to guide the choice of water or SP in other experimental mixtures. The Workable Now spread of concrete was in the minge of 110-13525% for bath water and SP, so water was selected due to vost. In addition, the spread values qualify the mixtures for hardened properties evaluation, Compressive Strength of POFA Alkali-Aetivated Concrete [0137] ‘The compressive strength of AAC specimens was conducted at three different ages, 3, 14 and 28 days for showing the influence of mixture proportions onthe sirens development with time (Table 4). In general, forthe developed POPA alkali-activated concrete hereia, the 28-day compressive strength ranged of 33 MPa to 49 MPa. The ‘compressive strength property was very mich dependent on the sodium hydroxide concentration, sodium silicate 10 sodium hydroxide ratio, alkali activator/POFA rato PAPOFA, CA/POFA and the chemical properties of POFA ‘asa binder It was also seen thatthe compressive strength ‘nereased with an increase in the quantity of POFA, a trend ‘that was evident for all the dare ages sind. TABLE 4 Velged POA saci once No NONI ” ww Mio Mis Mai sex) POFA, TAPOFA FATA CATA 2diys Hite 2hsys Malay = 1M Os ts 04s Oss Sa 3392 Os 10s 08S a 80 aS Ost ows oss 70 Os Toms 08s 3650 Shoe 380 Nouay = ta 06 1S 04S O88 3380 38STUS 2021/0039997 AI Merits of the Developed! Akali-Activated Conerete [0138] 1. The developed AAC utilizes an agricultural ‘waste material, palm oil fuel ash, dumped on landils, as the sole binder. [0139] 11 With respec othe environment the palm oil fo ash (POFA) alkali-aetivated concrete i sustainable and eco-tiendly due tthe huge availability of POPA, 1d] IHL With respect 10 United Nation sustainable development goals, the use of POFA significantly reduces the catbon footprint for conerete manufacture ‘hecause Portland cement is not used as cementitious binder [141] TV; The development of the innovative alkali ‘activated conerete is cheap in comparison with the cost ‘of OPC conerete, whieh then results in. substantial Savings in the cost of stnictiral and infinstrctural applications [0142] V. The beneficial use of POFA agricultural ‘wastes in the invention conserves hectares of lands curently used for landfills allowing the lands 10 be used constructively, efor the development of roads, buildings ete [0143] Vi. The concrete of the present disclosure proved t have excellent fresh and hardened properties, In some case achieving 3 compressive strength of almost $0 MPa, making it suitable for most structural applications. 1. A-conerete composition, comprising: a toated palm oil feel ash, wherein the treated palm oil fue ash is the only binder present; a fine aggregate; fa coarse aggregate; and ‘an alkali activator comprising. an_ aqueous solution of ‘sodium hydroxide and sodium siete 2. The concrete composition of claim 1, wherein the treated palm ol fuel ash is present in an amount of 20 to 30 ‘wt. %, based on a total weight ofthe eonerete composition. 3. The concrete composition of cluim 1, wherein the treated palm oil fue ash is obtained sequentially from drying raw palm oil fuel ash at 80 to 120° C,, sieving toa particle size of less than 300 jm, a fist mechanical ball milling ‘aleining at $00 (0 600° C, and a second mechanical ball, nilling 4, The concrete composition of claim 1, wherein the teoated palm oil fuel ash has a median particle size (dg) oF 05 t0 204m, ‘6 The concrete composition of claim 1, wherein the treated palm oil fue ash comprises, as constitent oxides, 60 to T2Wh. %6 SiO, 410 8 wt. % ALOy, 310 7 wt. % FeO, 3108 wl % CaO, 1 to 5 wt % MyO, 310 7 wt. % KO, 02 05 wt % SO, 0. 10 0.25 wt. % Na,O. and I to $ wt. % ‘ofP,0,, exch based on total Weight of the tated palm oil, Tuck ash 1B Feb. 11, 2021 6. The concrete composition of claim 1, wherein the treated palm oil fuel ash comprises, as constituent oxides, 66 {0 68 WL % Si0,.6 10 7 Wl. %ALO,, $10 6.5 wt. %Fe.0s, 510.6. % CaO, 2.5 03.5 WL. %6MgO, 4.5 106 Wt. % KO, 03 10 0.35 wt. % SOs, 0.18 0 0.2 wt % NaO, and 3 104 WL % of P.0,, each Based on a total Weight ofthe treated palm oi fel ash 7. The concrete composition of claim 1, wherein the treated palm ol fel ash fas a loss on ignition (LOI) of less 3 Ww. %, based on a total Weight ofthe treated palm ei fuel ash, and a specific surface ara of 1.4 10 1.6 m/e. 8. The concrete composition of claim 1, wherein a weight ratio of a combined weight ofthe coarse agareyate and the fine aggregate tothe treated palm oil fel ash is 1:1 to 2:1 9. The concrete composition of claim 1, wherein the fine agoregate fas a fineness modulus of 18 to 21 and saturated surface dry (SSD) specific gravity of 2.5 to 27. 10, The conerete composition of claim 1, wherein the coarse agaregate has a saturated surface dry (SSD) specific aravity of 2410 26, IL. The concrete composition of claim 1, wherein the coarse aggregate hus bimodal particle size distribution ‘witha first mode panicle size of 4 106 mm and second mode particle size of 210 3 mm, and a wherein a weight ratio of coarse aggregate having the frst mode patcle size to coarse ‘aggregate having the second mode partile size is 1:1 to 31 12. The concrete composition of claim 1, wherein a ‘weight ratio ofthe eoarse aggregate tothe fine aggregate is 1:10 2 18, The concrete composition of claim 1, wherein the alkali activator is formed from an aqueous solution of sodium hydroxide having a sodium hydroxide conceatration of 10 t0 14 moll. 14, The conerete composition of claim 1, wherein ‘weight ratio ofthe alkali activator tothe treated palm oil fuel ash is O81 10.071 18, The conerete composition of claim 1, wherwin a ‘weight mito of sodium silicate to sadam hydroxide is I: t0 31 16, The conerete composition of claim 1, which has ‘weight ratio of water to the treated palin ol fuel ash of 0.05 10 098 17. The concrete composition of claim 1, which consists ‘ofthe treated palm ol fuel ash, the coarse aggregate the fine ‘aggregate, sodium hydroxide, sodium sliete, and water 18. Acured concrete comprising the conerete composition of claim 1 in cured form, 19, The cured conerete oF claim 18, which has @ 28-day ‘compressive strength of 33 t0 49 MPs. 20, The cured concrete of claim 18, which bus unit weight of 2200 10 2300 kin

US20210039997A1 Palm Oil Fuel Ash in Concrete

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