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<p>The current work aims to establish a basic correlation between the bulk behaviour of blend powders and their physical characteristics. Particle size distribution, particle density, loose-poured bulk density, tapped density, Hausner ratio, Carr index, and angle of repose are determined for the fundamental characteristics of the samples. Inter-particle forces of attraction in the bulk blend powder are measured by cohesion, adhesion and unconfined yield stress. In light of this, scanning electron microscope (SEM) analysis and surface roughness have been employed to characterise industrial waste blends, focusing on their mineral composition and particle morphology. A total of 10 different blends of ordinary Portland cement (OPC), pond fly ash (PFA), fly ash (FA) and flue gas desulfurisation gypsum (FGDG) in different proportions have been characterized. Based on the present study, it has been revealed that, substitution of PFA with flue gas desulfurization gypsum (FGDG) in blends resulted in lower surface roughness values, as both materials fall within the easy-flowing zone of flow function curves. In contrast, replacing FGDG with fly ash (FA) in blends significantly increased surface roughness due to FA’s cohesive nature. Flow function tests showed that FA-based blends exhibited higher unconfined yield strengths (up to 7.5&#xa0;kPa) and internal friction angles (up to 58°), confirming their cohesive nature, while PFA-based blends displayed lower resistance to flow. OPC recorded the highest wall friction angle (~ 30°), while FA had the lowest (~ 22°). Surface roughness was evaluated via SEM and Gwyddion software. PFA-based blends exhibited low surface roughness (R<sub>a</sub>: 0.025–0.068&#xa0;μm), while FA-based blends showed significantly higher roughness (R<sub>a</sub>: 13.66–17.44&#xa0;μm), correlating with increased cohesion. These findings highlight the distinct flow behaviors of the supplementary cementitious materials, contributing to a broader understanding of the cohesion and adhesion mechanisms between particles within the blends. Furthermore, the flowability and surface roughness characteristics of both individual particles and blended powders provide valuable inputs for the design of pipelines and hoppers by accounting for internal friction in the cement manufacturing process. Additionally, the results obtained from the characterization of ternary blends offer useful insights into their potential application in the production of masonry construction products.</p> Graphical Abstract <p></p>

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Effect of particle morphology and surface roughness on the flow behaviour of cementitious blends

  • 期刊论文

  • 发表日期：

    2026年4月20日

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  • Chandan Kishor,
  • S. S. Mallick,
  • Sayan Sadhu,
  • Himanshu Chawla

摘要

The current work aims to establish a basic correlation between the bulk behaviour of blend powders and their physical characteristics. Particle size distribution, particle density, loose-poured bulk density, tapped density, Hausner ratio, Carr index, and angle of repose are determined for the fundamental characteristics of the samples. Inter-particle forces of attraction in the bulk blend powder are measured by cohesion, adhesion and unconfined yield stress. In light of this, scanning electron microscope (SEM) analysis and surface roughness have been employed to characterise industrial waste blends, focusing on their mineral composition and particle morphology. A total of 10 different blends of ordinary Portland cement (OPC), pond fly ash (PFA), fly ash (FA) and flue gas desulfurisation gypsum (FGDG) in different proportions have been characterized. Based on the present study, it has been revealed that, substitution of PFA with flue gas desulfurization gypsum (FGDG) in blends resulted in lower surface roughness values, as both materials fall within the easy-flowing zone of flow function curves. In contrast, replacing FGDG with fly ash (FA) in blends significantly increased surface roughness due to FA’s cohesive nature. Flow function tests showed that FA-based blends exhibited higher unconfined yield strengths (up to 7.5 kPa) and internal friction angles (up to 58°), confirming their cohesive nature, while PFA-based blends displayed lower resistance to flow. OPC recorded the highest wall friction angle (~ 30°), while FA had the lowest (~ 22°). Surface roughness was evaluated via SEM and Gwyddion software. PFA-based blends exhibited low surface roughness (Ra: 0.025–0.068 μm), while FA-based blends showed significantly higher roughness (Ra: 13.66–17.44 μm), correlating with increased cohesion. These findings highlight the distinct flow behaviors of the supplementary cementitious materials, contributing to a broader understanding of the cohesion and adhesion mechanisms between particles within the blends. Furthermore, the flowability and surface roughness characteristics of both individual particles and blended powders provide valuable inputs for the design of pipelines and hoppers by accounting for internal friction in the cement manufacturing process. Additionally, the results obtained from the characterization of ternary blends offer useful insights into their potential application in the production of masonry construction products.

Graphical Abstract