1. Introduction
Green, low-carbon, and sustainable development has become a global strategy. The coarse aggregate in concrete mostly uses ordinary crushed stone, and with the over-exploitation of natural resources, natural crushed stone aggregates are increasingly being depleted, and their price is rising. The exploitation of a large number of mineral resources has a great impact on the natural environment [
1]. Coal gangue is the solid waste discharged in the process of coal mining and washing, accounting for 10~25% of coal mining [
2,
3]. Large quantities of coal gangue accumulations have an important impact on groundwater, soil, and other environments. Non-spontaneous combustion coal gangue (NCCG) is a newly mined, non-spontaneous combustion, black-gray rock. The most practical and economical method is to use it as concrete aggregate. NCCG as aggregate is an important way to realize bulk utilization of coal gangue and reduce the environmental damage caused by spontaneous combustion of coal gangue accumulation. At the same time, it also reduces the extraction of natural sand and crushed stone aggregate, which is conducive to protecting the ecological environment.
There has been extensive research on the mechanics, shrinkage characteristics, and durability of spontaneous combustion coal gangue as coarse- and fine-aggregate concrete [
4,
5], while there has been less research on NCCG. The comprehensive utilization of coal gangue has become a popular topic in the industry. At present, coal gangue is mainly used for the construction of roads, railways, sintered bricks, and concrete components [
6,
7]. Due to the layered characteristics of coal gangue aggregate [
3], the content of coal gangue aggregate has the greatest effect on the compressive strength of concrete. Liu et al. [
8] used 100% coal gangue to prepare concrete, and the elastic modulus was reduced by 57%. It has also been found that the 28 d elastic modulus of concrete mixed with 100% spontaneous combustion coal gangue decreases by 32% [
9]. Zhao et al. [
10] found that the original coal gangue has a negative impact on the mechanical properties and durability of concrete, and the higher the content of the original coal gangue, the greater the degradation in the strength, elastic modulus, wear resistance, impermeability, and frost resistance of the concrete. Fly ash has a dual improvement effect on the interfacial transition zone (ITZ) performance and mortar pore structure of coal gangue concrete. Due to the rougher surface of coal gangue compared to crushed stone, the microspheres of fly ash are easily enriched [
11]. When the coarse and fine aggregates of concrete are all coal gangue, the compressive strength at 28 d is 52.24 MPa and 44.80 MPa, respectively, when the W/B ratios are 0.4 and 0.5, which meet the strength requirements of C30~C50 concrete [
12]. Qiu et al. [
13] found that with the increase in the freeze–thaw cycles, the overall change trend of relative mass, compressive strength, and dynamic elastic modulus of coal gangue aggregate concrete decreased gradually, and the above indexes declined rapidly with the increase in coal gangue content.
Durability is an important index used to evaluate the environmental effects of concrete. Ma et al. [
2] prepared concrete with original aggregate and 700 °C calcined coal gangue as coarse aggregate. The study found that calcined coal gangue aggregate showed greater advantages in sulfate attack resistance, and the concrete with calcined coal gangue coarse aggregate showed better frost resistance in the early stage. It is recommended that the content of coal gangue coarse aggregate is 30~50%. The freeze–thaw damage value of coal gangue concrete has a linear positive correlation with the freeze–thaw cycles, and the damage value increases rapidly with the increase in coal gangue content [
13].
In summary, a large number of researchers have demonstrated that using coal gangue as coarse aggregate is feasible, but a large content of coal gangue has a negative effect on the mechanical and durability of concrete. Few scholars have paid attention to the study of “strong wrapped weak” concrete. Using high-performance mortars to wrap NCCG coarse aggregate to prepare NCCG coarse-aggregate high-performance concrete will greatly improve the durability of concrete. In this study, NCCG was used as a coarse aggregate to prepare high-performance concrete. The research variables include W/B ratios (0.20, 0.22, 0.25, and 0.28), NCCG coarse-aggregate replacement rates (0 vt%, 30 vt%, 45 vt%, and 60 vt%), fly ash–slag mass ratios (replacement rate 30%, fly ash and slag mass ratio 0:3, 1:2, 1:1, 2:1, and 3:0), and silica fume coating (NCCG coarse aggregate coated with silica fume pastes). The workability (slump and expansion), mechanical properties (compressive strength, splitting tensile strength, and axial compressive strength), and durability (frost resistance, sulfate resistance, and carbonation resistance) of concrete were tested. Based on scanning electron microscopy (SEM) testing, the impact mechanism of NCCG coarse aggregate on the ITZ and the durability performance of concrete was analyzed. Finally, based on the grey system GM(1,1) prediction model, the life prediction of NCCG coarse-aggregate high-performance concrete was carried out.
4. Discussion on the Feasibility of Preparing High-Performance Concrete with NCCG Coarse Aggregate
The research on green high-performance concrete mostly focuses on the replacement of cement, focusing on the study of hydration characteristics [
23,
24,
25]. In recent years, many studies have been carried out on the preparation of high-performance concrete by substituting aggregate, including waste glass fine aggregate [
26], ceramic aggregate [
27], and coral aggregate [
28]. Various types of coal gangue, such as calcined coal gangue, spontaneous combustion coal gangue, and non-spontaneous combustion coal gangue, have been proven to be used as coarse aggregate of concrete. However, with the increase in coal gangue content, the mechanical and durability of concrete decrease greatly [
3,
14,
29], and the content of coal gangue should not be too large (≤30%). High-performance concrete takes durability as the main design index. By adding fly ash, slag, and silica fume, the pore structure of the paste is improved and the permeability of the concrete is reduced. Coal gangue is mostly layered rock, and its water absorption rate and crushing index value are higher than those of ordinary crushed stone, which will inevitably have a negative impact on the strength and durability of concrete.
With the increase in NCCG coarse-aggregate content, the compressive strength of concrete decreases approximately linearly. When the NCCG coarse-aggregate content is 60%, the 28 d compressive strength is still greater than 50 MPa, showing excellent compressive strength. Through the durability index test, the NCCG coarse-aggregate content has the greatest effect on frost resistance and sulfate resistance. After 150 freeze–thaw cycles, the mass loss rate of concrete with 60% NCCG coarse-aggregate content is 1.41%, and the relative dynamic elastic modulus loss rate is 25.25%, which is far lower than the requirements of 5% and 40% of the standard specifications, showing excellent frost resistance durability. After 240 d of sulfate attack, the compressive strength of high-performance concrete with 0% and 30% NCCG coarse-aggregate content increased. However, the compressive strength of high-performance concrete with 45% and 60% NCCG coarse-aggregate content decreased by 2.19% and 12.42%, respectively; that is, in a sulfate attack environment, NCCG coarse-aggregate content should not be higher than 45%. NCCG coarse-aggregate content has no significant effect on the anti-carbonization performance. At 20% CO2 concentration, the carbonization depth of 200 d is less than 3 mm, showing excellent anti-carbonization performance. In the high-carbonization environment, the NCCG coarse-aggregate content can be greater than 60%.
5. Prediction of Frost Resistance Durability Life of NCCG Coarse-Aggregate High-Performance Concrete Based on Grey System GM(1,1)
The service life is related to the performance of the material in a given environment and the deterioration mechanism of the material, which is an inherent property of the material [
30]. Most coal mines in China are located in cold regions, such as Northwest, North, and Northeast China, and concrete is mostly subjected to freeze–thaw cycles. Grey system theory is a means to quantitatively predict the future state based on the known information in the evolution process of objective things, and has become an important method for the study of the uncertainty problem [
31]. The grey system GM(1,1) refers to a grey model with a first-order variable. With the help of known information or laws to find realistic laws, all the variable sequences called grey can be directly generated by some combination to weaken their randomness and directly show their basic regularity.
5.1. Grey System Theory GM(1,1)
- (1)
Establishment of grey system GM(1,1) prediction model
Set the sequence operator based on the known data as:
Accumulate X
(0) once; the generated sequence of one accumulation is:
where X
(1)(k) =
= X
(1)(k−1) + X
(0)(k), k represents a time series (25 freeze–thaw cycles in this paper).
The first derivative of the time function t and the differential equation in the whitening form of GM(1,1) can be obtained:
Equation (3) is the GM(1,1) grey model established in this paper, which is a first-order differential equation. The values of a and u in the equation are calculated from durability test data. Denote the parameter sequence as
; this can be estimated by the least square method:
. Suppose that B is a data matrix, Y
n is a data column, and the representations of B and Y
n are shown in Equations (4) and (5):
The solution of GM(1,1) whitening equation is calculated as follows:
- (2)
Model prediction value restoration
Since the data calculated by the GM(1,1) model represent the one-time cumulative amount of X
(0), all the data
(1)(k + 1) obtained by the GM(1,1) model must be reduced to
(0)(k + 1) to be used.
- (3)
Grey system GM (1,1) prediction model test
GM(1,1) system theory is a prediction calculation method; the accuracy of this prediction model needs to be tested. The commonly used methods include relative error detection, correlation, and mean square error ratio–small error probability calculation [
31]. The mean square error ratio–small error probability calculation method is used for testing.
Based on the prediction error
(
k) of each group of test blocks, and assuming that X
(0) is the original sequence,
is the simulation error sequence, and
is the residual sequence, then:
The mean square error ratio is c = for a very given c0 > 0; when c < c0, the model is the mean square error ratio qualified model.
The small error probability value p = P{
} for a given p
0 > 0; when p > p
0, this model is called a qualified model of the small error probability value. In the grey system GM(1,1) prediction model test, the smaller the c value and the larger the
p value, the better. According to the c value and
p value, the prediction model accuracy can be divided into four levels, as shown in
Table 7.
5.2. Frost Resistance Life of NCCG Coarse-Aggregate High-Performance Concrete
In practical engineering, the frost resistance of concrete is often evaluated in years, rather than times; furthermore, the freeze–thaw cycles vary from place to place, and the same limit times will cause the life of concrete in different regions to fail to meet the predetermined requirements. Therefore, in order to predict the actual life of the concrete using the freeze–thaw test, the measured freeze–thaw index should be transformed into the corresponding years that can be used for the actual calculation. The relationship between the freeze–thaw cycles in the test and nature is expressed as [
32]:
where
T is the actual freeze-resistance life of concrete in the natural environment, and n is the number of freeze–thaw cycles when the residual value of the relative dynamic elastic modulus measured by the experiment is 0.6. n is the number of average annual freeze–thaw cycles in each region and
K is the ratio of the rapid freeze–thaw cycles in the laboratory to the freeze–thaw cycles in nature; the general ratio is 10~15, and 14 was selected for this study.
Table 8 shows the annual actual freeze–thaw cycles in Northwest, North, and Northeast China.
The relative dynamic elastic modulus loss rate of less than 0.6 is considered as the freeze–thaw damage standard for concrete. Based on Equations (1)–(14), the accuracy grade of the prediction model of all samples is level one; that is, the grey system theory GM(1,1) can be applied to the prediction of the durability of NCCG coarse-aggregate high-performance concrete. The frost resistance life of NCCG coarse-aggregate high-performance concrete with 12 mix proportions was calculated, as shown in
Table 9.
The service life of NCCG high-performance concrete is most affected by the replacement rate of coarse aggregate. The greater the replacement rate, the shorter the service life. In North China, NCCG coarse aggregate is used to prepare high-performance concrete, and the recommended content is 60%. In the Northwest and Northeast regions, the recommended content is 45%. Considering that most of the actual projects are in a humid environment, the freeze–thaw cycle process is carried out under unsaturated water conditions. Therefore, the service life predicted by the grey system GM(1,1) is the lowest service life, and the NCCG coarse-aggregate content can be greatly increased; it is feasible that the NCCG coarse-aggregate content is more than 60%.