Formulation of Porous Packing Materials for Dissolved Acetylene Cylinders

Porosity and the Thermodynamic Stability of Stored Acetylene: An Engineering Boundary

The safe containment of acetylene at pressures exceeding atmospheric requires that the gas be dissolved in a suitable solvent, typically acetone or dimethylformamide (DMF), which is itself retained within a highly porous solid matrix filling the cylinder. The critical function of the packing material is not merely to absorb the solvent but to subdivide the gas phase into microscopically fine channels whose dimensions prevent the propagation of a decomposition wave. When acetylene decomposes exothermically, the reaction can accelerate into a detonation if the gas pockets exceed a critical diameter; the packing material must therefore present a continuous network of capillaries with diameters below 50 µm and, in most regulatory regimes, a macro-porosity exceeding 80 % as determined by mercury intrusion porosimetry in accordance with the principles of ISO 15901‑1:2005. This capillary subdivision works in concert with the solvent’s stabilizing effect, where acetylene molecules are kept in solution, reducing the local concentration of free gas. The packing, however, introduces its own failure modes: settlement during thermal cycling, chemical attack by trace impurities in the acetylene stream, and embrittlement due to cyclic absorption‑desorption of the solvent. The formulation of the porous mass must therefore reconcile a high total porosity, a narrow pore‑throat size distribution, sufficient compressive strength to resist vibration and impact during transport, and long‑term chemical compatibility with the solvent‑acetylene system at pressures up to 2.5 MPa at 15 °C, as specified in the filling pressure tables of EN 1800:1998.

The industrial benchmark for porous fill materials has long been the calcium silicate hydrate (C‑S‑H) phase produced from a slurry of Portland cement, finely divided silica, water, and various pore‑forming or fiber‑reinforcing additions. The slurry is poured into the cylinder, vibrated to eliminate large voids, and then subjected to a controlled high‑pressure steam cure—typically autoclaving at saturated steam pressures between 0.8 MPa and 1.6 MPa for 8 h to 24 h—to convert the lime‑silica reactants into a crystalline tobermorite or xonotlite binder with a high specific surface area and inherent micro‑porosity. This hydrothermal processing transforms the initially weak green body into a semi‑rigid monolithic block that fills the cylinder completely, eliminating the need for segmental insert assemblies and minimizing the risk of vibration‑induced compaction that plagued earlier designs using asbestos‑cement cartridges. The as‑cured monolith must then be dehydrated, an operation that exerts severe stress on the pore structure: rapid heating drives off free water, generating internal steam pressures that can burst pore walls if the permeability is insufficient. The art of formulation is therefore centered on controlling the gel‑space ratio, the particle packing density of the raw silica flour, and the rheology of the fresh slurry so that the hardened product develops a bimodal pore system—large transport pores (5 µm to 50 µm) for solvent mobility and small gel pores (10 nm to 100 nm) for surface area—without sacrificing the compressive strength threshold of 2.0 MPa (unconfined) mandated by ISO 3807:2013, Annex A.

When High‑Alumina Cements Are Substituted into Portland‑Based Formulations

The shift from ordinary Portland cement (OPC) to calcium aluminate cement (CAC) in the binder phase was driven not by cost but by severe durability failures recorded in the field when OPC‑based fills were exposed to the acidic by‑products of acetylene generation—specifically acetic acid residues carried over from the generation process or formed through hydrolysis of trace esters in technical‑grade acetone. OPC hydrates, primarily portlandite (Ca(OH)₂) and C‑S‑H gel, react with acetic acid to form calcium acetate, a highly soluble salt whose dissolution creates progressive washout channels through the monolith. These channels, once exceeding 2 mm in diameter, can coalesce into a connected pathway of free gas volume, compromising the flame‑arresting mechanism. CAC‑based binders, when hydrated under the same hydrothermal conditions, produce a matrix dominated by C₃AH₆ and gibbsite (AH₃), which display markedly lower solubility in organic acid environments. The formulation must, however, contend with the rapid setting of CAC, which can limit the working time of the slurry to less than 45 min at 20 °C unless the retarder system is carefully adjusted. Sodium gluconate at 0.05 wt% to 0.15 wt% of binder weight is effective in extending pot life to 90 min, but excessive dosage leads to a depression of early compressive strength and a coarsening of the gel pore structure due to delayed formation of the hydrated aluminate phases. Further complicating the picture, CAC‑based formulations exhibit a property cliff‑edge at a silica‑to‑alumina molar ratio of approximately 1.5: below this value, the autoclaved product contains residual unreacted C₃AH₆ that hydrates further during solvent saturation, causing a delayed expansion of up to 0.8 % linear strain, which can crack the fill and create preferential gas pathways. This dimensional instability is assessed via the drying‑shrinkage and wetting‑expansion test outlined in ASTM C596‑18, with an acceptance criterion of ≤ 0.15 % length change after immersion in acetone for 72 h.

The slurry preparation itself represents a high‑shear mixing operation where the order of addition, the shear rate, and the temperature control are directly linked to the final pore architecture. A typical production‑scale mixing vessel of 500 L capacity equipped with a double‑helical ribbon impeller operating at 60 rpm is used to pre‑disperse the silica flour (median particle size 25 µm, BET surface area 5 m²/g) into the gauging water containing the dissolved retarder and any surfactant additives. Once a stable suspension is achieved, the cementitious binder is introduced under a vacuum of ‑0.08 MPa to minimize air entrainment, and the rotational speed is increased to 120 rpm for a final high‑torque dispersion phase lasting 15 min. The resulting slurry must exhibit a flow‑table spread diameter of 180 mm to 220 mm per ASTM C230/C230M‑21 to permit air‑free filling of the cylinder neck, yet must not segregate during vibration. Rheological measurements on a rotational viscometer at a shear rate of 10 s⁻¹ typically show a shear stress between 80 Pa and 150 Pa for a pumpable mix; values outside this range correlate with either sedimentation of the larger silica particles (yielding a dense bottom layer of low porosity) or excessive yield stress that traps air bubbles during filling. Each cylinder, after filling, is placed on a vibratory table operating at 50 Hz with an amplitude of 0.5 mm for a period of 90 s to achieve a bulk density of 0.55 g/cm³ to 0.65 g/cm³ on a dry basis, a parameter that is checked by gamma‑ray attenuation scanning in some high‑volume manufacturing lines to ensure homogeneity.

What Limits the Solvent Loading Capacity in Calcium Silicate Monoliths?

The solvent retention capacity of the packing, measured as the mass of acetone absorbed per unit volume of fill, is directly proportional to the open porosity accessible to the solvent. While total porosity measured by water saturation can exceed 85 vol%, the effective porosity for acetone uptake is invariably lower due to the existence of dead‑end pores and pores with throat diameters below the percolation threshold for the solvent at operating temperatures. The formulation challenge is to maximize the pore volume fraction that participates in capillary imbibition under the driving force of the pressure differential during solvent injection. The acetone injection process, typically carried out at 0.3 MPa to 0.5 MPa through a lance inserted to the cylinder bottom, must achieve a uniform saturation profile within the fill without creating dry regions near the cylinder wall, a defect known as “coring.” Cores arise when the local permeability of the packing is insufficient to allow solvent flow at the imposed pressure gradient; the fluid instead channels along the cylinder wall, bypassing the bulk of the fill. Permeability, computed via Darcy’s law from pressure‑decay measurements on dry cylinders, must exceed 10⁻¹⁴ m² for acetone at 20 °C to avoid coring in standard 40 L cylinders with a fill length of 1.2 m. To engineer this permeability, the formulation may incorporate fugitive pore‑forming agents—micronized polystyrene beads that volatilize during the pre‑cure drying stage at 100 °C—leaving behind well‑defined spherical voids of 20 µm to 40 µm diameter. However, the residue from incomplete burnout, typically less than 0.02 wt% carbonaceous char, can catalyze the polymerization of acetylene under certain conditions, a risk that must be mitigated by a subsequent oxidation step in an atmosphere of 5 % oxygen in nitrogen at 350 °C for 4 h, as required by the cylinder manufacturer’s internal specification when using organic template materials.

A less hazardous alternative to organic pore formers is the inclusion of 0.5 wt% to 2.0 wt% of alkali‑soluble glass fibers that, after the hydrothermal cure, are leached out by circulating dilute sodium hydroxide solution through the fill, generating a network of micro‑channels with a controlled tortuosity. This chemical leaching process, while effective, introduces an additional wash‑and‑dry cycle that can itself cause cracking if the fill is not properly supported. The drying schedule after leaching is the single most critical process window: water removal must proceed under conditions where the capillary pressure never exceeds the tensile strength of the solid skeleton. For a calcium silicate monolith with a median pore radius of 15 nm, the maximum capillary tension at the drying front can exceed 10 MPa, far above the material’s measured tensile strength of 0.8 MPa to 1.5 MPa as determined by the Brazilian splitting test on cored specimens per ASTM C1006‑07(2013). To prevent fracture, the relative humidity in the drying chamber is lowered in a stepwise profile: 95 % RH for the first 24 h, 85 % for the next 24 h, and then a ramp to 10 % over 72 h, with the temperature maintained at 60 °C throughout. Any deviation exceeding ±5 % RH during the initial stage results in a detectable acoustic emission count exceeding 20 events/min, indicative of micro‑crack coalescence, and the cylinder is quarantined for ultrasonic tomography inspection.

An entirely different approach to the packing structure replaces the monolithic in‑situ cured fill with a pre‑formed, segmented porous insert fabricated from a sintered calcium silicate or a lightweight ceramic foam. In this design, individual annular blocks, each 150 mm in height and machined to an outer diameter 2 mm smaller than the cylinder internal wall, are stacked inside the cylinder and compressed with a spring‑loaded top plate. The advantage of this method is that the pore structure is generated in a separate, highly controlled sintering process, allowing for a more uniform pore size distribution and eliminating the large‑scale drying stresses that plague monolithic fills. The blocks are produced by mixing the powdered raw materials—typically a blend of wollastonite, silica, and a borosilicate glass frit as flux—with a urethane foam template of 30 ppi (pores per linear inch), followed by high‑temperature firing at 1100 °C where the organic foam pyrolyzes and the ceramic particles partially melt to form a reticulated strut network. The resulting cellular solid has a porosity of 88 % to 92 %, a strut density of 1.8 g/cm³, and a uniaxial compressive strength of 3.5 MPa to 5.0 MPa. The drawback, however, is the presence of a continuous annular gap between the insert and the cylinder wall, a space that must be carefully filled with a compliant sealant—typically a fluoroelastomer‑based putty—to prevent preferential gas accumulation under the wall. The sealant itself must not exude plasticizer into the acetone, which would alter the solvent’s acetylene‑holding capacity and potentially contaminate downstream welding or cutting operations.

Thermal Decomposition Resistance and the Backflash Test Paradigm

The definitive performance test for any porous packing formulation is the backflash test, designed to verify that the combination of solvent and filler can arrest a flame front propagating from a localized ignition source within the cylinder. The test is codified in ISO 3807:2013, Annex C, and requires that a cylinder pre‑filled with acetone and charged with acetylene to its maximum settled pressure at 15 °C be subjected to a decomposition initiated by a fusible plug or an igniter wire located at the bottom of the cylinder. The propagation of the reaction front is monitored by thermocouples spaced along the cylinder axis; a “pass” rating demands that no thermocouple above the ignition point records a temperature rise exceeding 100 °C above ambient, and that the cylinder wall temperature at a point 200 mm above the fuse remains below 180 °C. The failure mode—a sustained propagation—is typically linked to one of three formulation‑related defects: (1) the presence of continuous pores with an equivalent diameter larger than the acetylene detonation cell size at the test pressure, (2) a local deficiency in acetone saturation owing to packing non‑uniformity, or (3) catalytic contaminants in the filler that lower the activation energy for acetylene polymerization. Copper, even in trace concentrations below 10 ppm, is a well‑known ignition sensitizer due to the formation of explosive copper acetylide, and thus all brass and bronze components in the mixing and filling system must be excluded from contact with the slurry or the raw materials. Stainless steel of the 316L grade is the minimum acceptable material for all product‑contact surfaces, verified by X‑ray fluorescence spectrometric screening of raw material batches per ASTM E1621‑21.

In formulations where high‑temperature calcined diatomaceous earth is used as a micro‑porous aggregate, the presence of residual iron oxides—typically 1 wt% to 4 wt% as Fe₂O₃—has been shown in laboratory-scale adiabatic calorimetry (using an ARC 254 operated in heat‑wait‑seek mode) to catalyze the exothermic oligomerization of acetylene at approximately 280 °C, a temperature that can be reached locally during flashback. The activation energy for the initial decomposition step drops from 185 kJ/mol for pure calcium silicate to 135 kJ/mol for the diatomite‑bearing mix, a reduction that brings the onset temperature into the range achievable by a backflash event. Consequently, diatomaceous earth can be used only if the total iron content, expressed as Fe₂O₃, is below 1.0 wt% and if the calcination temperature of the source material exceeds 900 °C to passivate the surface sites. This restriction effectively limits the supply chain to a small number of calcined diatomite grades, a fact that has significant implications for batch‑to‑batch consistency and requires each received lot to be tested for loss on ignition (ASTM D7348‑21) and for metal content by inductively coupled plasma optical emission spectroscopy.

The fiber reinforcement strategy is another formulation variable with a direct, non‑linear impact on backflash performance. While chopped glass fibers of 12 mm length and 10 µm diameter at a loading of 2 vol% increase the fracture toughness of the green body during handling and early‑stage drying, they also introduce a preferred orientation plane normal to the vibratory filling direction. In the backflash test, these planes can act as high‑permeability pathways for flame propagation if the fiber‑matrix interface debonds under thermal shock. The coefficient of thermal expansion mismatch between the calcium silicate matrix (6 × 10⁻⁶ K⁻¹) and E‑glass fibers (5 × 10⁻⁶ K⁻¹) is minimal, but the rapid temperature spike of a backflash event—typically a heating rate of 200 K/s—generates transient tensile stresses at the interface that exceed the bond strength, which is only 0.4 MPa to 0.8 MPa as measured by the single‑fiber pull‑out test. To mitigate this, fibers with a proprietary alkali‑resistant coating (approximately 0.2 wt% sizing of an epoxy‑functional silane) are used, and the slurry pH is adjusted to 10.5 ± 0.2 to optimize the silane hydrolysis and condensation reaction during the initial setting stage. This chemical bonding is verified by a post‑cure microscopic examination of the fracture surface: a suitable bond yields a cohesive failure in the matrix rather than a clean fiber pull‑out, and the specification mandates that ≥ 80 % of observed fibers in a representative polished section exhibit matrix‑adherent residue.

Typical raw material specifications for a mixed‑binder porous packing formulation.
MaterialSpecification ParameterRequired ValueTest Method
Portland cement (Type I/II)Blaine fineness380420 m²/kgASTM C204‑18
Silica flourSiO₂ content≥ 99.0 wt%ASTM C25‑19
Calcium aluminate cementAl₂O₃ content≥ 70.0 wt%EN 196‑2:2013
Chopped AR‑glass fiberLoss on ignition (sizing content)0.180.25 wt%ISO 1887:2014
Calcined diatomaceous earthTotal Fe₂O₃≤ 1.0 wt%ICP‑OES after acid digestion
Process waterChloride content≤ 50 ppmASTM D512‑15
Sodium gluconate (retarder)Purity≥ 98%USP‑NF monograph

Beyond chemical composition, the meso‑scale pore structure of the finished packing is evaluated by a combination of mercury intrusion porosimetry and capillary flow porometry. The former, performed with a porosimeter capable of a maximum pressure of 414 MPa, yields the total pore volume and the median pore‑throat diameter; a typical acceptable range for the median is 2.0 µm to 5.0 µm, with ≤ 5 % of the total intrusion volume contributed by pores larger than 25 µm. The latter technique, using a Galwick solution with a surface tension of 15.9 mN/m, provides the through‑pore size distribution and the smallest constriction along the flow path—the “bubble point” diameter—which is specified as ≤ 15 µm for a properly interconnected pore network. These two measurements, taken together, characterize both the storage capacity and the fluid transport properties of the fill; a discrepancy between the intrusion pore volume and the through‑pore volume exceeding 15 % indicates a high fraction of ink‑bottle pores that may not fully saturate with acetone, leading to a reduced effective solvent capacity and a consequent lowering of the maximum permissible acetylene charge per fill.

Filling the cylinder with acetylene after solvent saturation introduces an additional set of stresses. As acetylene dissolves in the acetone, the liquid phase expands by approximately 3 vol% to 5 vol%, exerting a hydrostatic pressure on the pore walls. If the solid framework has a low elastic modulus—below 400 MPa—this expansion can cause a permanent dilation of the monolith, increasing the total void volume and allowing pockets of free gas to form. The modulus of the autoclaved calcium silicate binder is a strong function of the CaO/SiO₂ molar ratio, reaching a maximum of about 1.2 GPa at a ratio of 0.83 (the tobermorite stoichiometry). The art of the formulation is to target this exact ratio through careful batching, but the industrial reality of cement composition variability—a typical OPC can have a CaO content fluctuating by ±1.5 % between lots—forces the use of X‑ray diffractometric Rietveld analysis on each cement delivery to adjust the silica addition dynamically. This adaptive batching is automated in modern filling plants via a closed‑loop control system that measures the oxide composition from a fused‑bead XRF sample within 8 min of sampling and adjusts the weigh‑feeder setpoints accordingly, maintaining the CaO/SiO₂ ratio within ±0.02 of the target.

How Micro‑structural Gradients Develop During Autoclave Processing

A largely invisible but performance‑critical phenomenon in monolithic fills is the formation of a radial gradient in pore structure induced by the temperature and moisture distribution within the cylinder during the autoclave cycle. The steel cylinder wall, with a thermal conductivity of approximately 50 W/(m·K), heats far more rapidly than the aqueous slurry core, which has a conductivity of 0.6 W/(m·K). This mismatch results in an initial temperature differential of up to 40 K between the skin and the center of a 250 mm diameter cylinder, a gradient that persists for the first 60 min of the heat‑up phase. Under these conditions, the dissolution of silica and the precipitation of C‑S‑H occur preferentially near the wall, forming a dense outer rim of lower porosity—typically 72 % to 78 %—while the core remains under‑reacted and more highly porous, at 85 % to 90 %. This gradient is detrimental because the dense rim impedes the subsequent drying process, trapping moisture in the core and promoting hydraulic overpressure during early solvent filling. One remedial approach, validated on a production‑scale autoclave of 6 m internal diameter processing 200 cylinders per batch, is to introduce a pre‑heating dwell at 80 °C for 3 h under atmospheric steam, allowing the entire mass to reach near‑isothermal conditions before pressurization. This step extends the total cycle time by 15 % but reduces the radial porosity differential to less than 4 %, as confirmed by X‑ray computed tomography scans of sliced core samples. The CT analysis, conducted at a resolution of 50 µm/voxel, reveals that the rim‑core transition becomes sufficiently gradual that no sharp boundary delineates a permeability contrast layer, thus avoiding the delamination that had been observed in earlier single‑ramp cycles at the cylinder‑fill interface during acetone injection.

The chemical durability of the packing in the presence of the solvent is evaluated through an accelerated aging test, typically a 30‑day immersion of a representative monolith block in acetone at 60 °C under a nitrogen blanket, with periodic measurements of the leached calcium concentration in the liquid phase by EDTA complexometric titration. A calcium release exceeding 200 ppm after 30 days is indicative of continued hydration or carbonation of residual free lime, a defect that can consume acetone through aldol condensation side reactions catalyzed by basic sites on the calcium hydroxide. Formulations that incorporate a reactive silica excess, such that the final pH of an aqueous slurry extract is 9.0 ± 0.5, exhibit calcium releases below 50 ppm, owing to the complete consumption of portlandite during the autoclave reaction. This pH specification has become a routine quality‑control check on every production batch, performed by preparing a 10 % slurry of the crushed packing in deionized water and measuring the pH after 15 min of stirring, with a meter calibrated to ±0.02 pH units.

Key performance properties and test standards for porous packing in dissolved acetylene service.
PropertyStandard / MethodAcceptance CriterionEquipment
Total porosity (water saturation)ISO 3807:2013, Annex A≥ 83 vol%Analytical balance (0.01 g), vacuum vessel
Median pore‑throat diameterISO 15901‑1:2005 (mercury intrusion)2.05.0 µmPorosimeter, max pressure 414 MPa
Uniaxial compressive strength (dry)ASTM C109/C109M‑20b≥ 2.0 MPaUniversal testing machine, load cell 50 kN
Linear expansion after acetone immersionASTM C596‑18≤ 0.15%Length comparator, 0.001 mm resolution
Backflash propagation resistanceISO 3807:2013, Annex CNo thermocouple rise >100 °C above ambientInstrumented cylinder, data logger (100 Hz)
Leachable calcium in acetoneInternal extraction method (60 °C, 30 d)≤ 200 ppmEDTA titration burette, 0.01 M
Slurry bulk density (green)Volumetric cylinder/vibration method0.550.65 g/cm³ (dry basis)Graduated cylinder, vibration table

The regulatory framework governing these products is multi‑jurisdictional, with EN 1800:1998 providing the design and inspection requirements for transportable refillable welded steel cylinders for acetylene, and ISO 3807:2013 specifying the detailed testing of the porous mass. Compliance with these standards is not a matter of single batch certification; it requires an ongoing production surveillance program wherein one cylinder from every 200 consecutively filled is subjected to a destructive examination that includes a backflash test, porosity analysis, and a macro‑optical inspection of the fill‑to‑wall interface for shrinkage gaps exceeding 0.5 mm. Any failure triggers a recall of the preceding 200 cylinders, an event that in practice occurs less than once per 10,000 units in plants operating under a statistical process control regime with a CpK of at least 1.67. The interface gap inspection is particularly sensitive to the thermal history of the cylinder after filling: cylinders that are exposed to ambient temperatures below ‑10 °C prior to testing can show an apparent gap due to differential thermal contraction between the steel (α = 12 × 10⁻⁶ K⁻¹) and the calcium silicate (α = 6 × 10⁻⁶ K⁻¹), but this gap must close upon return to 20 °C. A gap that persists at 20 °C is a true shrinkage defect, often caused by a deficiency in the initial water content of the slurry, which reduces the extent of hydration and leaves a permanently undersized monolith. The optimum water‑to‑binder ratio, therefore, lies not at the stoichiometric requirement for complete hydrothermal reaction but at a slightly higher value—typically 0.65 to 0.75 by mass for a blended OPC‑CAC‑silica system—to provide the expansion‑compensating formation of ettringite or analogous phases during the early stages of autoclaving, a technique borrowed from shrinkage‑compensated cement technology (ASTM C845‑18).

The industry has also explored non‑cementitious binder systems, notably those based on sodium silicate activated with an organic ester hardener, which eliminate the portlandite durability problem entirely. In these geopolymer‑like formulations, a mixture of metakaolin, silica fume (BET surface area 15 m²/g), and sodium silicate solution (modulus SiO₂/Na₂O = 1.6) is blended to a paste, poured into the cylinder, and cured at 90 °C for 12 h. The product is a potassium‑based aluminosilicate network with an intrinsic nano‑porosity that provides a surface area exceeding 80 m²/g and a total water‑accessible porosity of 78 % to 82 %. While the porosity is slightly lower than optimally formulated C‑S‑H systems, the pore size distribution is more uniform and the material shows practically zero calcium extraction in acetone. The limitation that has prevented widespread adoption is the brittleness of the metakaolin‑based binder; its critical stress intensity factor, Kᵻc, measured by the single‑edge notched beam technique in three‑point bending (ASTM C1421‑18), is 0.2 MPa·m¹/² compared to 0.5 MPa·m¹/² for fiber‑reinforced tobermorite, making the fill susceptible to catastrophic cracking during cylinder impact testing (the drop test of EN 1800 from 1.2 m onto a steel plate). Ongoing development in this area incorporates nano‑silica‑coated polymeric micro‑fibers that dissolve in the alkaline environment after setting, leaving behind a secondary network of micro‑cracks that act as a crack‑deflection mechanism, but published data for this specific configuration is limited to laboratory‑scale cylinders of 10 L water capacity, and scaling to full 50 L production units has not yet been validated by an independent notified body.

The operational boundary conditions for the packing material continue to tighten as acetylene distribution chains extend into regions with ambient temperatures exceeding 50 °C. At these temperatures, the solvent vapor pressure rises, and the equilibrium pressure of dissolved acetylene increases disproportionately, challenging both the mechanical stability of the fill and the decomposition suppression mechanism. The packing must therefore be designed for a service pressure envelope that extends to at least 3.0 MPa at 65 °C, requiring a porosity‑corrected compressive strength that provides a safety factor of 4.0 against pore collapse as calculated by finite element analysis using the Drucker‑Prager failure criterion for the porous solid. Formulations that meet this requirement invariably incorporate a minimum cement content of 35 wt% of the total dry solids, a figure derived from multivariate regression of compressive strength data on over 800 production‑scale specimens, where the independent variables included the binder type, the autoclave temperature ramp rate, and the silica‑to‑binder ratio. The associated model, validated on an independent test set of 120 cylinders, showed an adjusted R² of 0.93, with the most significant single predictor being the product of the autoclave soak temperature and the square root of time, a kinetic maturity parameter known to govern the degree of tobermorite crystallinity.

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