Effect of synthesis parameters on the quality of construction and demolition wastes (CDW) geopolymers

Synthesis and Characterization of Novel Hybrid Wollastonite-Metakaolin-Based Geopolymers

Over the past few decades, researchers have focused on developing new production methods for geopolymers to improve their properties for use in multiple applications as a functional material. This study introduces a new geopolymer system based on wollastonite and metakaolin as precursors. The role of wollastonite was also explored alongside metakaolin in geopolymers. Geopolymers were synthesized by adding wollastonite to metakaolin in different ratios: 0 wt.%, 12.5 wt.%, 25 wt.%, and 50 wt.%. The alkaline activator was then mixed with the powder, wollastonite, and metakaolin to prepare the geopolymers. In addition to mechanical tests, the hardened geopolymers were characterized using XRD, TGA, and SEM techniques. The findings revealed that adding wollastonite in amounts of 0 wt.%-12.5 wt.% did not affect the strength of the geopolymers. Increasing wollastonite between 25 wt.% and 50 wt.% significantly increased the geopolymers' flexural and compressive strength from 3 MPa to 12.3 MPa and from 23 MPa to 54 MPa, respectively. The use of wollastonite as a precursor also led to fundamental changes in the microstructural structure of the geopolymer matrix: a new crystal phase, (Ca5(SiO4)2(OH)2), calciochondrodite was formed, and the Si-Al-Na crystal phase disappeared, leading to significant changes in the amorphous phase.

Clean production of geopolymers as an opportunity for sustainable development of the construction industry

Large-scale cement production generates significant amounts of carbon dioxide from the breakdown of limestone, contributing to environmental pollution. Clean production of eco-friendly three-dimensional geopolymers can be used as environmentally friendly building materials. Replacing Portland cement with eco-friendly materials correlates with reduced energy consumption, costs, and negative environmental impact. In addition, geopolymer cement has above-average physical and chemical properties, which in many cases exceed conventional Portland cement. The literature review summarizes the latest research in the production of geopolymers following the principles of green chemistry and sustainable development goals. Examples of upcycling of construction waste, industrial waste (fly ash, silica fume, slag, tailing), demolition waste, agriculture solid waste (rice husk, palm oil), and mining waste into functional geopolymer materials will be discussed. Additionally, the review focused on innovative applications and physicochemical properties of functional geopolymer materials.

Mechanical properties of low calcium alkali activated binder system under ambient curing conditions

These days, the construction industry is facing sustainability issues, leading to the selection of greener, low-carbon, alkali-activated materials. This study examines a low calcium alkali activated system composed of three constituents (ceramic brick, metakaolin waste, and phosphogypsum). The AAB compositions consist of the primary precursor, waste ceramic brick, which is increasingly (20-100 wt%) replaced with waste metakaolin. The alkaline solution was made of sodium hydroxide and water; dosage depended on the Na2O/Al2O3 ratio (1.00-1.36). The AAB specimens were inspected by using XRD (X-ray diffraction) and FT-IR (Fourier transform infrared spectroscopy) methods for the evaluation of mineral composition, accompanied by SEM-EDS (scanning electron microscopy & energy dispersive X-ray spectroscopy) for the analysis of the microstructure. The compressive strength after 7, 28 and 90 days, along with water absorption and softening coefficient were determined. Also, mixture calorimetry was established. The results have shown that the initial materials are suitable for producing medium-strength alkali-activated binder under ambient temperature. The maximum compressive strength was reached by using the combination of 80% CBW and 20% MKW (13.9 and 21.2 MPa after 28 and 90 days respectively). The compressive strength development was linked with the formation N-A-S-H gel and faujasite type zeolite. A higher level of geopolymerization in composition with metakaolin waste led to lower compressive strength. Consequently, binding materials with low demand of high final and especially early compressive strength could be produced under ambient temperature curing, making them more sustainable.

Modification of Recycled Concrete Aggregate and Its Use in Concrete: An Overview of Research Progress

The differences in physical properties, chemical properties, and mechanical properties between reclaimed concrete aggregate and natural aggregate are discussed in this paper. In this paper, the commonly used improvement techniques of recycled concrete aggregate are reviewed. Physical modification involves peeling the attached mortar layer using mechanical and thermodynamic means, including mechanical grinding and shaping, heat treatment, and microwave or electric pulse treatment. Chemical modification is based on the chemical reaction of some materials with recycled aggregate attached mortar, including acid treatment removal, water glass strengthening, carbonation strengthening, inorganic slurry strengthening, and polymer strengthening. Microbial modification is mainly based on the metabolic activity of specific microorganisms that induce carbon deposition modification. The results show that the reinforced technology of recycled aggregate has made some progress in improving the performance of recycled aggregate, but there are still some problems, such as inconsistent strengthening effects and the unstable compatibility of composite materials. In this paper, future research directions, such as the development of new strengthening materials and the integration of multi-functional strengthening technology, are described in order to provide some theoretical support for the utilization of recycled concrete aggregate.

Development of Alkali Activated Inorganic Foams Based on Construction and Demolition Wastes for Thermal Insulation Applications

Nowadays, the construction industry is challenged not only by increasingly strict environmental regulations, but also by a shortage of raw materials and additives. It is critical to find new sources with which the circular economy and zero waste approach can be achieved. Promising candidates are alkali activated cements (AAC), which offer the potential to convert industrial wastes into higher added value products. The aim of the present research is to develop waste-based AAC foams with thermal insulation properties. During the experiments, pozzolanic materials (blast furnace slag, fly ash, and metakaolin) and waste concrete powder were used to produce first dense and then foamed structural materials. The effects of the concrete fractions, the relative proportions of each fraction, the liquid/solid ratio, and the amount of foaming agents on the physical properties were investigated. A correlation between macroscopic properties (strength, porosity, and thermal conductivity) and micro/macro structure was examined. It was found that concrete waste itself is suitable for the production of AACs, but when combined with other aluminosilicate source, the strength can be increased from 10 MPa up to 47 MPa. The thermal conductivity (0.049 W/mK) of the produced non-flammable foams is comparable to commercially available insulating materials.

Development of ambient cured geopolymer binders based on brick waste and processed glass waste

The current study focuses on the development of high sustainability geopolymer binders prepared from brick waste (BW), devitrified glass waste (DGW), and metakaolin (MK) as precursors, as well as sodium glass liquid (SGL) derived from DGW as alkali hardener. An algorithmic mixture design was used to target the chemical molar ratios of SiO2/Al2O3 and Na2O/SiO2, and the physical ratio of liquid/solid (L/S), involving curing under ambient temperature. Rheological characteristics, mechanical strengths, and microstructural properties of optimized geopolymers were investigated using rotational viscometry, compressive strength measurements, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and Fourier-transform infrared spectroscopy (FTIR). The results indicated that a greater content of DGW compared to BW caused lower yield stress and plastic viscosity. Moreover, geopolymer binders made with SGL and reduced amount of commercial sodium silicate (SS) showed a stable polymer network with compact microstructure, achieving results comparable to the control mixture with NaOH solution. Also, it was possible to improve the strengths of BW binders by including a combined 50% DGW + 50% MK precursor with different contents. FTIR analyses identified the formation of a corrosive component in the form of dehydrated Si-O(Na) when SGL replaced NaOH with a similar SS amount and chemical factors, whereas more Q1 and Q0 silica species was formed in hardener containing SGL with reduced commercial SS, confirming the sustainable nature of the new BW + DGW + MK binders with SGL.

Investigation of Mechanical Properties and Microstructure of Construction- and Demolition-Waste-Based Geopolymers

Construction and demolition waste (CDW) is the third-most abundant waste generated annually in the countries of the European Union. One of the alternatives to the use of these wastes is geopolymeric materials. Partial replacement of commonly used raw materials for the production of these materials can help reduce the number of landfills and the consumption of natural resources. In this study, the authors partially replaced metakaolin and fly ash with clay bricks and concrete debris. The research method in article is connected with analysis of microstructures and the mechanical and physical properties of the geopolymers. The results obtained show the possibility of manufacturing useful construction materials based on industrial byproducts (fly ash) and CDW. Compressive strength and flexural strength were, for samples containing metakaolin, 20.1 MPa and 5.3 MPa, respectively. Geopolymers containing fly ash displayed 19.7 MPa of compressive strength and 3.0 MPa of flexural strength. The results for both synthesized materials give them perspectives for future applications in the construction industry.

Waste Clay Bricks as a Geopolymer Binder for Pavement Construction

Geopolymer binders that combine aluminosilicate materials (i.e., precursors) with alkali activators are a viable and environmentally friendly alternative to ordinary Portland cement. While fly ash, slag, silica fume, and metakaolin are the most extensively investigated precursor materials, recent studies demonstrate the feasibility of using low amorphous aluminosilicates (LAA) for geopolymer synthesis. Waste clay bricks (WCB) make an excellent LAA material for producing geopolymer binders, considering their chemical and mineralogical properties. Geopolymer binders with enhanced mechanical properties can be produced either by blending WCB with other aluminosilicate materials or by using WCB as the sole precursor, while providing appropriate production conditions, such as high-temperature curing. Until now, in pavement construction, WCB has been investigated only as a subbase material or as an aggregate for concrete. Since WCB is a potential geopolymer source material, it can also function as an alternative cementitious material (ACM), and stabilizing material in pavement construction. This work reviews the recent studies on producing WCB-based geopolymers, with the focus particularly on the properties of raw materials, activator types and their concentrations, curing conditions, blended geopolymer systems, and the mechanical properties of WCB-based geopolymer binders. Simultaneously, different pavement design requirements and currently available specifications for the use of geopolymer concrete were correlated to evaluate their feasibility as an ACM in pavement construction. Based on the current literature, WCB can be proposed as a suitable ACM to develop pavement-grade concrete and more promising results can be obtained by blending WCB with high-calcium sources, such as slag. Therefore, comprehensive studies on geopolymer concrete development, durability, and field performance are recommended.

Reusing Construction and Demolition Waste to Prepare Alkali-Activated Cement

Large amounts of waste are derived not only from construction processes, but also the demolition of existing buildings. Such waste occupies large volumes in landfills, which makes its final disposal difficult and expensive. Reusing this waste type is generally limited to being employed as filler material or recycled aggregate in concrete, which limits its valorisation. The present work proposes reusing construction and demolition waste to manufacture alkali-activated cement to improve its sustainability and recovery. Construction and demolition waste (C&DW) from a demolition waste collection plant in Valencia (Spain) was physically and chemically characterised. This residue contained large fractions of concrete, mortar, bricks, and other ceramic materials. X-ray fluorescence (XRF) analysis showed that its chemical composition was mainly CaO, SiO₂ and Al₂O₃. X-ray diffraction (XRD) analysis revealed that it presented some crystalline products, and quartz (SiO₂) and calcite (CaCO₃) were the main components. Blends of C&DW and blast furnace slag (BFS) were alkali-activated with mixtures of sodium hydroxide and sodium silicate. The corresponding pastes were characterised by techniques such as thermogravimetry and scanning electron microscopy (SEM). The alkali-activated mortars were prepared, and the resulting mortars’ compressive strength was determined, which was as high as 58 MPa with the 50% C&DW-50% BFS mixture. This work concluded that it is possible to make new sustainable binders by the alkali activation of C&DW-BFS without using Portland cement.

Accelerated Curing for Glass-Based Mortars Using Water at 80 °C

The substitution of river sand with glass aggregate (GA) and cement with glass powder (GP) is a mainstream method to recycle waste glass. Traditionally, standard curing was widely used for glass-based mortars. However, it is time-consuming and cannot address low mechanical strengths of the early-age mortars. Therefore, the effect of water curing at 80 °C on the properties of GA mortars is investigated. Furthermore, the effect of the GP size is also considered. Results show that compared with the expansion of alkali-silica reaction (ASR), water curing at 80 °C has a negligible effect on the volume change. Moreover, the compressive strength of GA mortars under 1-day water curing at 80 °C is comparable with that under 28-day water curing at 20 °C. Therefore, the 1-day water curing at 80 °C is proposed as an accelerated curing method for GA mortars. On the other hand, the addition of GP with the mean size of 28.3 and 47.9 μm can effectively mitigate the ASR expansion of GA mortars. Compared with the size of 28.3 μm, GA mortars containing GP (47.9 μm) always obtain higher compressive strength. In particular, when applying the 1-day water curing at 80 °C, GA mortars containing GP (47.9 μm) can even gain higher strength than those containing fly ash.

Recycling of Mining Waste in the Production of Masonry Units

Masonry units made of clay or Autoclaved Aerated Concrete (AAC) are widely used in constructions from Romania and other countries. Masonry units with superior mechanical and thermal characteristics can improve the energy efficiency of buildings, especially when they are used as the main solutions for building envelope construction. Their production in recent years has increased vertiginously to meet the increased demand. Manufactured with diversified geometries, different mechanical and/or thermal characteristics have a high volume in the mass of the building and a major influence in their carbon footprint. Starting from the current context regarding the target imposed by the long-term strategy of built environment decarbonization, the aim of the paper is to analyze the potential of reusing mining waste in the production of masonry units. Mining waste represents the highest share of waste generated at national level and may represent a valuable resource for the construction industry, facilitating the creation of new jobs and support for economic development. This review presents the interest in integrating mining wastes in masonry unit production and the technical characteristics of the masonry units in which they have been used as raw materials in different percentages. Critical assessment framework using SWOT analysis highlights the key sustainability aspects (technical, environmental, social, economic) providing a comprehensive and systematic analysis of the advantages and disadvantages regarding the integration of mining waste as secondary raw materials into masonry units production.

Petrography of construction and demolition waste (CDW) from Abruzzo region (Central Italy)

The density, colour and texture, plus mineral and chemical features of 18 ceramic-like CDW samples from the Abruzzo region (Central Italy) were characterised. The concretes, natural stones, tiles, roof-tiles, bricks and perforated bricks are either aphanitic to porphyric. Concretes and natural stones are grey to white and tend to be > 2.0 g/cm³; the masonries are brown to reddish and close to < 2.0 g/cm³. Concrete and natural stone are rich or even exclusively made up of calcite, with high amounts of CaO (>40 wt%) and LOI (volatiles, CO₂ + H₂O). The masonries are instead calcite-, CaO- (<25 wt%) and LOI-poor (<8 wt%) but enriched in SiO₂ (45 to 70 wt%) stabilised as quartz and/or cristobalite, with significant amount of Al₂O₃ (12 to 20 wt%). S and Cl contents are similar among concrete, bricks and perforated bricks. The petrography of CDW concretes is similar among geographical areas with abundance of limestones used as aggregates. However, in limestone-poor areas CDW are SiO₂- and Al₂O₃-rich, reflecting the prevalent use of masonry and/or silicate-rich construction materials, implying that each geographical area is characterised by peculiar CDW composition. Therefore, the knowledge of mesoscopic, physical and petrographic aspects has to be known for planning adequate sorting methods, promoting upcycling reusing applications. Some of the studied CDW samples are susceptible to release relative high Cr and As content.

Properties of Inorganic Polymers Based on Ground Waste Concrete Containing CuO and ZnO Nanoparticles

The effect of copper oxide and zinc oxide nanoparticles (NPs) on the mechanical and thermal properties of ground waste concrete inorganic polymers (GWC IPs) has been investigated. NPs are added to GWC IPs at loadings of 0.1, 0.5, 1, and 2% w/w. The phase composition and microstructure of NPs GWC IPs have also been examined using X-ray diffraction (XRD), Raman spectroscopy and scanning electron microscope (SEM/EDS) techniques. Results show that the mechanical properties of GWC IPs are improved (23 MPa) due to addition of NPs (1% ZnO). In particular, GWC IPs embedded with 0.5% CuO and 1% ZnO NPs exhibited relatively improved compressive strength. The addition of NPs decreases the macroporosity and increases the mesoporosity of IPs matrix and decreases relatively the ability of IPs matrix to water absorption. The antimicrobial activity of GWC IPs doped with 0.5 and 1% CuO NPs against E. coli was also determined.

Mechanical Behavior Investigation of Reclaimed Asphalt Aggregate Concrete in a Cold Region

Recycled construction and demolition (C&D) waste can reduce the rebuild cost, and is environmentally friendly when recycled asphalt pavement (RAP) aggregate constitutes the main part. This paper investigated the mechanical performance of RAP concrete, and the applicability of RAP in road base layers also was discussed. Several mechanical laboratory tests were selected, including the unconfined compressive-strength, splitting-strength, and compressive-resilience modulus tests. The RAP concrete had a good road performance in a cold region, which was proved by the temperature-shrinkage test, dry-shrinkage test, freeze–thaw-cycle test, and water-stability test. Based on various cement dosages from 3.5% to 5.5% in RAP concrete mix design, three RAP aggregate replacement ratios (30%, 40%, and 50%) were selected to study the variation of mechanical properties with increasing curing time, and the optimal aggregate substitute ratio was determined. A scanning electron microscope (SEM) was used to observe the inner-structure interface between the asphalt binder and cement stone. A numerical model is presented to simulate the RAP compressive strength with respect to the effect of multiple parameters. The research results can provide a technical reference for RAP use in the reconstruction and expansion of low-grade highway projects.

Effect of Activating Solution Modulus on the Synthesis of Sustainable Geopolymer Binders Using Spent Oil Bleaching Earths as Precursor

The valorization of spent oil bleaching earths (SOBE) is crucial for the protection of the environment and the reuse of resources. In this research, alkali-activated binders were manufactured at room temperature using SOBE as a precursor by varying the mass ratio between the activating solutions of sodium silicate (Na2SiO3) and 6 M sodium hydroxide (NaOH) (activating solution modulus) (Na2SiO3/NaOH ratio = 1/1; 1/2; 1/3; 1/4) to investigate the influence on the technological properties of the materials. This process intends to evaluate the potential of SOBE, heat-treated at 550 °C (1 h), as a precursor of the reaction (source of aluminosilicates). Samples produced with higher amounts of sodium silicate developed a denser structure, with lower porosity and a higher amount of geopolymer gel. Maximum flexural (8.35 MPa) and compressive (28.4 MPa) strengths of samples cured at room temperature for 28 days were obtained with a Na2SiO3/NaOH mass ratio of 1/1. The study demonstrates that SOBE waste can be used as a precursor in the manufacture of geopolymer binders that show a good compromise between physical, mechanical and thermally insulating characteristics.

Physical and Mechanical Properties of Fly Ash Based Geopolymer Concrete Compared to Conventional Concrete

The potential of applying geopolymerization to a wide range of solid industrial waste and by-products is of great interest. In this research, the physical and mechanical properties of fly ash (FA)-based geopolymer concrete (GC), compared to those of cement concrete (CC), were studied. Three GCs with different content of FA and three appropriate CCs were designed, prepared, tested and evaluated. The results were compared with the requirements of Standards EN 206-1 and EN 1992-1-1. It was shown that in some cases minor adjustments of the regulations are needed, while in other cases complete revision is required. GC indicated competitive compressive strength compared to CC, tensile strength within the limits specified by Eurocode 2 for CC and modulus of elasticity about 50% less than that of CC. The ratio of binder (FA) to aggregates seems to have a significant effect on the properties of GC. The concrete with 750 kg/m3 FA seems to be the best choice taking into consideration both engineering and environmental criteria.

Current Applications of Recycled Aggregates from Construction and Demolition: A Review

A literature review comprising 163 publications published over a period of 26 years from 1992 to 2018 is presented in this paper. This review discusses the generation and recycling of construction and demolition waste (CDW) as well as its main uses as raw materials for the construction engineering sector. This review pays attention to the use of CDW aggregates for sand, pavements/roads, bricks, ceramics, cementitious materials, and concrete productions, as well its uses as eco-friendly materials for water decontamination. The physical-chemical and mechanical characteristics of recycled aggregates play an important role in their correctly chosen applications. The results found in this literature survey allow us to conclude that recycled aggregates from CDW can be successfully used to produce construction materials with quality comparable to those produced with natural aggregates. We concluded that the use of CDWs as raw materials for manufacturing new construction materials is technically feasible, economical, and constitutes an environmentally friendly approach for a future construction and demolition waste management strategy.

Editorial for Special Issue: Alkali Activated Materials: Advances, Innovations, Future Trends

Alkali activated materials (AAMs), also named geopolymers or inorganic polymers, are materials that are produced when alkaline solutions react with precursors containing aluminosilicate phases [...]

Factors Affecting Alkali Activation of Laterite Acid Leaching Residues

In this experimental study, the alkali activation of acid leaching residues using a mixture of sodium hydroxide (NaOH) and alkaline sodium silicate solution (Na2SiO3) as activators is investigated. The residues were also calcined at 800 and 1000 °C for 2 h or mixed with metakaolin (MK) in order to increase their reactivity. The effect of several parameters, namely the H2O/Na2O and SiO2/Na2O ratios present in the activating solution, the pre–curing time (4–24 h), the curing temperature (40–80 °C), the curing time (24 or 48 h), and the ageing period (7–28 days) on the properties of the produced alkali activated materials (AAMs), including compressive strength, porosity, water absorption, and density, was explored. Analytical techniques, namely X-ray diffraction (XRD), Fourier transform infrared (FTIR) spectroscopy, scanning electron microscopy (SEM), and elemental mapping analysis were used for the identification of the morphology and structure of the final products. The experimental results show that the laterite acid leaching residues cannot be alkali activated in an unaltered state, and the compressive strength of the produced AAMs barely reaches 1.4 MPa, while the mixing of the residues with 10 wt% metakaolin results in noticeably higher compressive strength (41 MPa). Moreover, the calcination of residues at 800 and 1000 °C has practically no beneficial effect on alkali activation. Alkali activated materials produced under the optimum synthesis conditions were subjected to high temperature firing for 2 h and immersed in distilled water or acidic solution (1 mol L−1 HCl) for 7 and 30 days in order to assess their structural integrity under different environmental conditions. This study explores the potential of alkali activation of laterite leaching residues amended with the addition of metakaolin for the production of AAMS that can be used as binders or in several construction applications in order to enable their valorization and also improve the environmental sustainability of the metallurgical sector.

Marble Waste Valorization through Alkali Activation

In the present study, the valorization potential of marble waste in the presence of metakaolin via alkali activation was explored. The activating solution used consisted of NaOH and sodium silicate solutions. The effects of marble waste to metakaolin ratio, particle size of raw materials, curing temperature, and Na2O/SiO2 and H2O/Na2O molar ratios present in the activating solution on the main properties and the morphology of the produced alkali-activated materials (AAMs) was evaluated. The durability and structural integrity of the AAMs after firing at temperatures between 200 and 600 °C, immersion in deionized water and 1 mol/L NaCl solution for different time periods and subjection to freeze–thaw cycles were also investigated. Characterization techniques including Fourier transform infrared spectroscopy, X-ray diffraction, mercury intrusion porosimetry and scanning electron microscopy were used in order to study the structure of the produced AAMs. Τhe highest compressive strength (~36 MPa) was achieved by the AAMs prepared with marble waste to metakaolin mass ratio of 0.3 after curing at 40 °C. The results indicated that the utilization of marble waste in the presence of metakaolin enables the production of AAMs with good physical (porosity, density and water absorption) and mechanical properties, thus contributing to the valorization of this waste type and the reduction of the environmental footprint of the marble industry.

Transition to circular economy in the construction industry: Environmental aspects of waste brick recycling scenarios

The extensive exploitation of natural resources, together with an inefficient use of end-of-life materials, results in the generation of vast amounts of waste. The current material streams are to be reconsidered to mitigate the environmental burdens and achieve the sustainability goals. However, these intentions usually lead to material downcycling, which does not provide significant environmental benefits. In this paper, the potential of waste brick recycling is assessed from the environmental point of view as the recycling options of waste bricks attract an eminent attention due to rationalization and optimization of material streams, including transformation to the circular economy model according to the EU commitments. Three different scenarios are taken into account in that respect: replacement of natural aggregate, partial replacement of cement binder, and alkaline activation. The life cycle methodology is used at the assessment and the obtained results are presented on both midpoint and endpoint levels. The analysis of environmental impacts shows only minor improvements resulting from the replacement of natural aggregates by recycled waste bricks. The partial replacement of cement by waste bricks in powdered form can provide the most substantial benefits including decarbonization of the construction sector. The application of alkaline activators can harm the potential of alkali-activated materials considerably due to their negative effects on human health. A complex assessment of recycling scenarios is found to preferable to one-sided analyses aimed at carbon dioxide emission reduction only if a real sustainability without any hidden risks is to be achieved.

Valorization of Brick and Glass CDWs for the Development of Geopolymers Containing More Than 80% of Wastes

One of the areas of priority in a circular economy, regarding waste management, regards the valorization of construction and demolition wastes (CDW). This study suggests the synthesis of geopolymeric binders based almost entirely on construction and demolition wastes. Ceramic waste was used as the aluminosilicate precursor of the geopolymer synthesis, while glass waste was applied in the preparation of the activation solution. A fractional experimental design defined the optimum synthesis parameters, based on compressive strength values. The final products were characterized by means of X-Ray Diffraction (XRD), Fourier-Transform Infrared Spectroscopy (FTIR) and Scanning Electron Microscopy (SEM). The glass waste was appropriately processed in order to prepare the activation solution for the geopolymerization of brick waste. In this work, CDW-based geopolymers were produced with a compressive strength in the range 10–44 MPa. The developed products contained 80–90 wt.% CDWs, depending on the method of activator preparation.

Construction and Demolition Waste (CDW) Recycling—As Both Binder and Aggregates—In Alkali-Activated Materials: A Novel Re-Use Concept

This article demonstrates the possibility of producing alkali-activated materials (AAM) from a mixture of mechanically processed concrete, ceramic, masonry, and mortar wastes, as a sustainable alternative for recycling construction and demolition wastes (CDWs) under real conditions. The addition of 10% Portland cement allowed the materials to cure at room temperature (25 °C). CDW binder achieved a compressive strength of up to 43.9 MPa and it was classified as a general use and low heat of hydration cement according to ASTM C1157. The concrete produced with this cement and the crushed aggregates also from CDW reported a compressive strength of 33.9 MPa at 28 days of curing and it was possible to produce a high-class structural block with 26.1 MPa according to ASTM C90. These results are considered one option in making full use of CDWs as binder and aggregates, using alkaline activation technology thereby meeting the zero-waste objective within the concept of the circular economy.

Factors affecting co-valorization of fayalitic and ferronickel slags for the production of alkali activated materials

The first objective of this experimental study is the assessment of the alkali activation potential of two types of fayalitic slags, an as-received one (FS) and the one obtained after plasma treatment (FSP) of the initial FS, for the production of alkali activated materials (AAMs). Furthermore, the second objective is the elucidation of the co-valorization potential of FS and FSP slags when mixed with ferronickel (FeNi) slag (LS). The alkaline activating solution used was a mixture of sodium hydroxide (NaOH) and sodium silicate (Na₂SiO₃). The effect of various operating parameters, such as H₂O/Na₂O and SiO₂/Na₂O ratios present in the activating solution, curing temperature, curing period and ageing period on the compressive strength, density, water adsorption, porosity and toxicity of the produced AAMs was explored. The structural integrity of selected AAMs was investigated after firing specimens for 6 h at temperature up to 500 °C, immersion in distilled water and acidic solution or subjection to freeze-thaw cycles for a period of 7 or 30 days. The results of this study show that FS- and FSP-based AAMs acquire compressive strength of 44.8 MPa and 27.2 MPa, respectively. When FS and FSP were mixed with LS at 50:50%wt ratios the compressive strength of the produced specimens increased to 64.3 MPa and 45.8 MPa, respectively. Furthermore, selected AAMs produced after co-valorisation of slags retained sufficient compressive strength after firing at 500 °C, 45-68 MPa, and exhibited very low toxicity. These findings prove the alkali activation potential of fayalitic slags as well as their co-valorization with ferronickel slag for the production of AAMs, an approach which is in line with the principles of zero-waste and circular economy.

Properties of Inorganic Polymers Produced from Brick Waste and Metallurgical Slag

This paper explores the alkali activation potential of brick wastes and metallurgical slags. Inorganic polymers (IPs) were produced using an alkaline medium consisting of sodium hydroxide and sodium silicate solutions and the optimum synthesis conditions were determined. In this context, the variable parameters, such as solid to liquid (S/L) ratio, curing temperature (60, 80 and 90 °C) and ageing time (7 and 28 days) on the compressive strength and the morphology of the produced IPs were investigated. Specimens produced under the optimum synthesis conditions were subjected to high temperature firing and immersed in distilled water and acidic solutions for various periods of time, in order to assess their durability and structural integrity. The results showed that the IPs produced using a mix ratio of 50 wt % metallurgical slag and 50 wt % brick wastes, cured at 90 °C and aged for 7 days obtained the highest compressive strength (48.9 MPa). X-ray fluorescence analysis (XRF), particle size analysis, Fourier transform infrared spectroscopy (FTIR), mineralogical analysis (XRD), mercury intrusion porosimetry (MIP), scanning electron microscopy (SEM) and thermogravimetric (TG) analysis also confirmed the optimum microstructural characteristics and the chemical reactions that took place during synthesis. The overall results of this study indicate that the co-valorization of different waste streams, which are produced in large quantities and cause environmental problems if not properly managed, is a viable alternative for the production of binders or secondary construction materials with higher added value.

Solidification/stabilization of municipal solid waste incineration fly ash using uncalcined coal gangue-based alkali-activated cementitious materials

The proper disposal of municipal solid waste incineration fly ash (MSWI FA) is necessary due to the presence of hazardous metals (Cu²⁺, Zn²⁺, Pb²⁺ and Cd²⁺). The solidification/stabilization through alkali-activated cementitious materials (having aluminosilicates) is regarded as one of the best methods for its disposal. In this paper, an uncalcined coal gangue-based alkali-activated cementitious material was used to solidify the MSWI FA. The compressive strength of these cementitious materials was evaluated through different contents of alkali activators, SiO₂/Na₂O molar ratios, liquid/solid ratios and curing temperatures by utilizing a single-factor experiment. The specimens with the highest compressive strength (31.37 MPa) were used for solidification of MSWI FA. The results indicated that compressive strength decreased with the addition of MSWI FA which caused the higher leaching of heavy metals. The solidification efficiencies of Cu²⁺, Zn²⁺, Pb²⁺ and Cd²⁺ were more than 95%. In addition, leaching concentrations had not surpassed the critical limit up to 20% addition of MSWI FA in solidified samples and representing the potential application of these samples for construction and landfill purposes. Heavy metals in MSWI FA were solidified through physical encapsulation and chemical bonding which was verified by speciation analysis, X-ray diffraction, Fourier transform infrared spectrometry and scanning electron microscopy with energy dispersive spectrometry analyses.

The Potential of Ladle Slag and Electric Arc Furnace Slag use in Synthesizing Alkali Activated Materials; the Influence of Curing on Mechanical Properties

Alkali activation is studied as a potential technology to produce a group of high performance building materials from industrial residues such as metallurgical slag. Namely, slags containing aluminate and silicate form a useful solid material when activated by an alkaline solution. The alkali-activated (AA) slag-based materials are promising alternative products for civil engineering sector and industrial purposes. In the present study the locally available electric arc furnace steel slag (Slag A) and the ladle furnace basic slag (Slag R) from different metallurgical industries in Slovenia were selected for alkali activation because of promising amorphous Al/Si rich content. Different mixtures of selected precursors were prepared in the Slag A/Slag R ratios 1/0, 3/1, 1/1, 1/3 and 0/1 and further activated with potassium silicate using an activator to slag ratio of 1:2 in order to select the optimal composition with respect to their mechanical properties. Bending strength of investigated samples ranged between 4 and 18 MPa, whereas compressive strength varied between 30 and 60 MPa. The optimal mixture (Slag A/Slag R = 1/1) was further used to study strength development under the influence of different curing temperatures at room temperature (R. T.), and in a heat-chamber at 50, 70 and 90 °C, and the effects of curing time for 1, 3, 7 and 28 days was furthermore studied. The influence of curing time at room temperature on the mechanical strength at an early age was found to be nearly linear. Further, it was shown that specimens cured at 70 °C for 3 days attained almost identical (bending/compressive) strength to those cured at room temperature for 28 days. Additionally, microstructure evaluation of input materials and samples cured under different conditions was performed by means of XRD, FTIR, SEM and mercury intrusion porosimetry (MIP).

Assessment of Alkali Activation Potential of a Polish Ferronickel Slag

In this study, the alkali activation potential of a Polish ferronickel slag (PS), for the production of inorganic polymers (IPs), is investigated. The effect of the main synthesis parameters, i.e., strength of the activating solution, consisting of NaOH and Na2SiO3 solutions and affecting (SiO2 + Al2O3)/Na2O and other important molar ratios in the reactive paste, pre-curing period, curing temperature and time and ageing period was investigated. The structural integrity of the produced specimens was tested after their (i) immersion in distilled water and acidic solutions for a period of 7–30 days, and (ii) firing at temperatures between 200 °C and 1000 °C. Several analytical techniques including X-ray diffraction, X-ray fluorescence, Fourier transform infrared spectroscopy, Differential scanning analysis-Thermogravimetry and Scanning Electron Microscopy were used for the characterization of the produced IPs. Results show that under the optimum synthesis conditions the IPs obtain compressive strength that exceeds 65 MPa. An innovative aspect of this study is that after heating at 400 °C, the specimens acquire compressive strength of 115 MPa and this indicates that they can be also used as fire resistant materials. This study highlights the potential of alkali activation for the valorization of a ferronickel slag and the production of IPs that can be used as binders or in several construction applications, thus improving the sustainability of the metallurgical sector.

Laboratory Evaluation of Finely Milled Brick Debris as a Soil Stabilizer

Brick is one of the most common building materials, and it is also one of the largest components of waste generated from both construction and demolition. Reuse of this waste would reduce the environmental and social impacts of construction. One potential bulk use of such waste is as a cementing agent for soil stabilization. However, this is currently limited by the need to mill the residue to a particle size below 0.035 mm. In this study, the behavior of two soil types stabilized using alkali-activated brick dust was investigated. The unconfined compression strength at different curing temperatures and moistures and the use of different types and concentrations of alkaline activators were investigated. It was found that the addition of brick dust resulted in an increase in the soil strength between 1.7–2.3 times with respect to the non-stabilized material, suggesting that the resulting materials will find practical applications in construction.