The interface performance between clay–sand mixtures and concrete structures is governed by the mixture's composition and its physical properties. Moisture content and particle-size distribution play important roles in deciding the mixture's arrangement of soil particles, porosity, hydraulic conductivity and behaviour under various mechanical loadings. Application of a polymer interfacial coating can improve the bond performance between soils and concrete mainly via interfacial friction/mechanical interlocking. The present work analyses the development of interfacial strength between clay–sand mixtures and a polymer coating with changes in particle gradation. The multi-scale mechanisms at the interface are investigated, giving primary attention to soil porosity. A 50:50 clay–sand mixture exhibited a greater interfacial adhesive performance compared to other soil mixtures. In addition, the moisture-controlled pores and gradation-controlled pores demonstrated differences in macroscale interfacial strength. Both mercury intrusion porosimetry (MIP) and 129Xe nuclear magnetic resonance (NMR) were utilized to detect the pore structure of the mixtures. 129Xe-NMR revealed the pore distribution of the mixtures as ranging from macropores to nanopores, and MIP complemented the pore information by determining the critical pore entry diameter in the macropore regime. Mesopores dominated with increasing fine sand content until a threshold value was reached; thereafter, merging of pores occurred and macropores dominated.

The formation of iron-rich phyllosilicates can occur at different natural or engineered settings. In this study, the influence of pH in the hydrothermal synthesis of iron-rich phyllosilicates was investigated in the pH range 8.50–12.10 after the ageing of the precursor. The synthesized samples were characterized by powder X-ray diffraction, Raman and Mössbauer spectroscopies and transmission electron microscopy. Three domains of pH were identified, and these correlated with silica availability and its speciation in the solution. The formation of 1:1-type FeIII/FeII phyllosilicate was observed between pH 9.67 and 10.75. Above pH 10.75, two types of phyllosilicate-like mineral phases were observed. In addition to 1:1-type FeIII/FeII phyllosilicate, 2:1-type FeIII/FeII phyllosilicate was observed. Below pH 9.67, mainly amorphous silica and iron oxides were observed. The findings show that pH governed the crystallinity and nature of the obtained phyllosilicate-like phases.

Lightweight expanded clay aggregates (LWAs) are porous materials with low density and high strength (EN-13055-1), and they are important in sustainable construction through their lightweight nature and ability to provide thermal or acoustic insulation. The objective of this work was therefore to evaluate the preparation of LWAs using a smectite clay (M1 formulation), whose application in common ceramic production is difficult. An alternative approach was proposed for the valorization of phosphate sludge and a palygorskite-rich sediment by mixing them with expanded clay (M2 formulation) for LWA production. This could result in economically cost-effective products with significant environmental benefits. Pellets were prepared and fired at various temperatures (1100°C, 1125°C and 1150°C), and relevant properties such as bloating index, density, water absorption and compressive strength were determined. Additionally, the microstructure, mineralogical transformations and phase compositions under various sintering temperatures were investigated. Increasing the temperature from 1000°C to 1150°C significantly improved the expansion properties of LWAs, and 1150°C seemed to be the optimal firing temperature at which the best expansion properties were achieved. In addition, the incorporation of the selected waste improved the properties of the final products, leading to lower density, greater strength and greater bloating with the development of the internal pore structure as compared to the LWAs without this addition. Because of their low density (0.6 g cm–3) and sufficient compressive strength (0.86 MPa), the manufactured LWAs can be used in construction (as insulating panels or in lightweight concrete) and in green roofs.

In the present study, a comparison of the thermal-insulation and mechanical performances of cement and heat-stabilized compressed earthen blocks (CEBs) was carried out to determine the factors which influence those properties. The raw clays used consist mainly of kaolinite, orthoclase and quartz. The mechanical strength increased with increase in both the amount of cement added and the firing temperature. However, the responses are better for cement-stabilized CEBs. The thermal insulation of fired bricks is greater than that of cement-stabilized bricks. This difference was related to the decrease in porosity and the formation of continuous-surface. The decrease in thermal insulation is mainly related to the formation of continuous-surface in cement-stabilized CEBs, whereas in the fired CEBs, it is due to the modification of pore volume. The mineralogy of the raw clays is statistically correlated to porosity and continuous-surface development that were confirmed as the main factors in the modification of both the mechanical strength and the thermal insulation. In cement-stabilization, the decrease in insulation is due to the development of continuous surface, while for heat-stabilization, mineral transformations during the sintering reduced continuous-surface formation and the insulation was controlled by both radiation and reduced surface conduction. The influence of the mineralogy of the raw material shows that clay content favours the insulation in fired bricks obtained at T ≤ 1000°C, while sand contents favour densification. In contrast, clay contents reduce the mechanical response of cement-stabilized material due to limited cement–clay interactions. In general, the mechanical response is more favourable in cement stabilization, while thermal insulation is better in fired bricks.

The rheological properties of three Na-activated, trioctahedral Mg-bentonites (hectorite clay from the CMS Source Clay Project repository, saponite clay from Spain and stevensite clay from Rhassoul, Morocco) and a sepiolite clay from Greece were examined after dynamic ageing at temperatures up to 230°C. The 5% w/v suspensions were prepared by dispersing the clay mineral samples in distilled water. The suspensions underwent dynamic, thermal ageing for 16 h before determination of the viscosity, filtration loss, filter cake thickness and pH and the concentration of dissolved Na+ and Mg2+. Thermal ageing contributed to the dispersion of clay particles, with a direct effect on plastic and apparent viscosity, introducing pseudoplastic behaviour. With the exception of the stevensite clay at 230°C that displayed limited dissolution at 230°C and partial conversion to kerolite, the clays were stable at high temperatures. The Na-activation of all clays except for stevensite was not adversely affected by thermal ageing. Thermal ageing of stevensite at 230°C facilitated Na exchange and yielded suspension with high viscosity and low filtrate loss. Only the suspensions of hectorite and those of stevensite aged at 230°C met with American Petroleum Institute specifications. The thermal behaviour and rheological properties of the clays might be interpreted according to the intrinsic properties of the clay minerals, such as layer charge and charge distribution.

Natural sepiolite has great potential for application in wound healing, haemostasis and medicines. This paper introduces a versatile solid-state sintering technique for preparing sepiolite-based nanocomposites with enhanced antibacterial properties, and the physical, structural, rheological and antibacterial properties of which were determined to be enhanced. The incorporation of nanosized Ag and metal oxides into sepiolite composites results in a notable improvement in their antibacterial efficacy against Escherichia coli and Staphylococcus aureus in comparison to the unmodified sepiolite. With a low silver content of just 5%, the sepiolite–Ag composite achieves an antibacterial rate of ~100%. Furthermore, the rheological properties exhibited by the sepiolite composites are noteworthy, suggesting their suitability for use in wound-dressing applications due to their exceptional workability. The methodology employed in this research has the potential to offer a viable substitute for the production of economical and effective natural antibacterial nanocomposites.

Polymer-based composites modified with organoclay are economically beneficial candidates for a variety of applications. Different types of impurities accompany montmorillonite phases in various bentonites, which impact the quality and cost of organoclays and final composites. To obtain organoclays for clay composite applications, eight Iranian raw bentonites from different geographical locations were selected as the candidates and characterized by X-ray diffraction (XRD). Sample IB was chosen due to its high purity and lower cristobalite content than the other samples. It was purified by centrifugation or sedimentation methods using a sodium hexametaphosphate (NaHMP) dispersant. The cation-exchange capacity (CEC) was measured for bentonite before and after purification by sedimentation, and it showed a significant increase from 6.944 to 12.128 eq g–1, confirming successful purification. Organoclays were prepared using purified bentonite (sedimentation method) with two surfactants (cetyltrimethylammonium bromide and octadecylamine), and the amount of octadecylamine was optimized. Purified bentonite and organoclay were characterized by XRD, scanning electron microscopy (SEM) and X-ray fluorescence. The results indicate that most of the impurities were removed after purification, and the interlayer space of organoclays increased to 35 Å in the optimized sample prepared with an amount of octadecylamine that was twice the CEC in purified bentonite. The prepared organoclay was used to improve low-density polyethylene (LDPE) polymer properties. The clay–polymer composite properties were studied by field emission SEM, thermogravimetric analysis and tensile strength tests. The organoclay was fully dispersed in the LDPE matrix and in the sample with 5 wt.% of organoclay, where Ti (the temperature at which 10% of the sample is decomposed) and T50% (the midpoint of degradation) were 17°C and 13°C greater than those of polyethylene, respectively. Additionally, the sample residue with 5 wt.% of organoclay at 600°C was 43.4%. The tensile strength of polyethylene increased from 8.67 to 9.03 MPa in the sample with 4 wt.% of organoclay.