Assessment of Clayey Freshwater Sediments as Suitable Precursors for Alkaline Activation

One of the biggest challenges in the construction industry in recent times is the mitigation of the environmental impact of this sector, the reduction in dependence on primary raw materials, and the reduction in CO2 production while maintaining functional properties. Alkaline activation of a number of waste products represents a promising way to achieve the above-mentioned goals, but the availability of a number of waste products changes over time, especially in Europe. While freshwater sediments were in the past widely utilized as an agricultural fertilizer, recent precautions have significantly decreased such application, and thus new destinations must be delivered. To explore the potential of freshwater sediments, select samples from various locations were subjected to detailed characterization to verify the applicability of the material for alkali activation. As recognized, the selected sediments contain a substantial volume of desired mineralogical compounds that can serve, after 900 °C curing, as suitable precursors. Such samples have consequently activated the mixture of alkaline activators to obtain dense structures and were subjected to detailed investigation aimed at understanding the mechanical parameters. The obtained mechanical results ranging between 14.9 MPa and 36.8 MPa reveal the engineering potential of sediments for valorization through alkali activation and outline new research challenges in this area.

Influencing Factors of Sulfuric Acid Resistance of Ca-Rich Alkali-Activated Materials

In this paper, we distinguished the degradation of alkali-activated material (AAM) exposed to sulfuric acid as physical (scaling, spalling, cracking, breaking, etc.) and chemical degradation (neutralization), because the mechanisms of these two types of degradation are different. Then, the effects of curing method, raw materials, and their mixing proportions on the two kinds of degradation of AAMs containing GGBFS were investigated in detail, including liquid-filler ratio, component of alkali activator, chemical admixture, inactive filler alternative to fly ash (FA), addition of municipal waste incineration bottom ash (BA), etc. The experimental results show that (a) small liquid-filler ratio, heat-curing, and the use of blended alkali activator solution of sodium silicate and NaOH can reduce both physical and chemical degradation of AAMs; (b) large GGBFS content or AE agent addition decreases the physical degradation, but increases the chemical degradation; (c) using crushed stone powder to replace FA and adding BA or a retarder would increase the physical and chemical degradation; but (d) the use of drying shrinkage reducer composed of polyether derivatives does not affect acid resistance. We also discussed the applicability and limitation of XRD and SEM-EDS in analyzing the chemical compositions of Ca-rich AAMs exposed to sulfuric acid, and found that (e) XRD analysis can identify the gypsum formation, and the gypsum peak intensity is related to the physical degradation of the Ca-rich AAMs; (f) by SEM-EDS analysis, the decalcification and dealkalization of C-A-S-H gels can be judged from the decrease in the average Ca/Si atomic ratio and the average Na atomic percentage in the acid corrosion area, but dealumination can be only determined from the dissimilarity of Al and Si elemental maps; and (g) if the CaO/SO₃ molar ratio ranges from 0.8 to 1.0, gypsum formation can be estimated.

Optimization of Fly Ash-Slag One-Part Geopolymers with Improved Properties

One-part geopolymer concrete/mortar is a pre-mixed material made from industrial by-products and solid alkaline activators that only requires the addition of water for activation. Apart from being environmentally friendly, it also reduces complexity and improves consistency in the mixing process, leading to more efficient production and consistent material properties. However, developing one-part geopolymer concrete with desirable compressive strength is challenging because of the complexity of the chemical reaction involved, the variability of the raw materials used, and the need for precise control of curing conditions. Therefore, 80 different one-part geopolymer mixtures were compiled from the open literature in this study, and the effects of the constituent materials, the dosage of alkaline activators, curing condition, and water/binder ratio on the 28-day compressive strength of one-part geopolymer paste were examined in detail. An ANN model with the Levenberg-Marquardt algorithm was developed to estimate one-part geopolymer's compressive strength and its sensitivity to binder constituents and alkaline dosage. The ANN model's weights and biases were also used to develop a CPLEX-based optimization method for achieving maximum compressive strength. The results confirm that the compressive strength of one-part geopolymer pastes increased by increasing the Na₂O content of the alkaline source and the slag dosage; however, increasing the Na₂O content in alkaline sources beyond 6% by fly ash weight led to decreasing the compressive strength; therefore, the optimum alkaline activator dosage by weight of fly ash was to be 12% (i.e., 6% Na₂O). The proposed ANN model developed in this study can aid in the production and performance tuning of sustainable one-part geopolymer concrete and mortar for broader full-scale applications.

Proportioning Factors of Alkali-Activated Materials and Interaction Relationship Revealed by Response Surface Modeling

Alkali-activated fly-ash-slag blending materials (AA-FASMs) are gradually being studied and applied more because of their good performance. There are many factors affecting the alkali-activated system, and the effect of single-factor variation on the performance of AA-FASM has been mostly reported; however, there is a lack of unified understanding of the mechanical properties and microstructure of AA-FASM under curing conditions and multiple-factor interaction. Therefore, this study investigated the compressive strength development and reaction products of alkali-activated AA-FASM under three curing conditions including seal (S), dry (D) and water saturation (W). Based on the response surface model, the relationship between the interaction of slag content (W_SG), activator modulus (M) and activator dosage (R_A) on its strength was established. The results showed that the maximum compressive strength of AA-FASM after 28 days of sealed curing was about 59 MPa, while the strengths of dry- and water-saturation-cured specimens decreased by 9.8% and 13.7%, respectively. The seal-cured samples also had the smallest mass change rate and linear shrinkage and the most compact pore structure. Due to the adverse effects from a too-high or too-low modulus and dosage of the activators, the shapes of upward convex, slope and inclined convex were under the interaction of W_SG/M, W_SG/R_A and M/R_A, respectively. The correlation coefficient R² > 0.95 and p-value < 0.05 indicated that the proposed model could be used to predict strength development given the complex factors. Optimal proportioning and curing conditions were found to be W_SG = 50%, M = 1.4, R_A = 50% and sealed curing.

Evaluation of the Nature and Concentration of the Surfactant on the Properties of Red Mud/Metakaolin Porous Geopolymers Foamed with Aluminium

The chemical foaming technique is possibly the most common method of producing porous geopolymers. Despite this, to date, the role of the content and type of surfactant on the pore size distribution of porous geopolymers is not fully perceived, as constant surfactant dosages are usually employed. In addition, the comparison of literature studies is challenging since a distinct mixture of designs is employed. This investigation intends to provide additional insights on the topic, focusing on synthesizing red mud/metakaolin geopolymer foams and envisioning their use in thermal insulating applications. Various mixtures were prepared using three commercially available surfactants, namely Hostapur OSB, sodium dodecyl sulfate (SDS), and Triton X114. The content of the surfactant (0.025, 0.05, and 0.075 wt.%) and the amount of the foaming agent (aluminum powder, Al; 0.05, 0.075, and 0.10 wt.%) was modified, keeping the binder composition constant and the physical properties of the produced geopolymers were characterized. Results show that the combination between sodium dodecyl sulfate (0.025 wt.%) and aluminum (0.10 wt.%) leads to the strongest reduction in the foam density, the lowest value here reported being -400 kg/m³. On the other hand, samples produced with Hostapur OSB have much higher open porosity (up to 47.7%) and water absorption (up to 80.4%) values, showing that this surfactant leads to a pore network with higher connectivity. In addition, the microstructure of the foams, particularly pore morphology (size and shape) and connectivity between the produced pores are highly dependent on the type of surfactant, sodium dodecyl sulfate generating coarser pore size distribution with round, but mostly closed pores, while a narrower pore size distribution coupled with smaller size pores is seen with the Hostapur. These results suggest the feasibility of tuning the foams' properties (porosity and mechanical performance) according to the application by the proper combination of the type of surfactant and their concentration, enabling their use as thermal and acoustic insulators or as filters/membranes in wastewater treatment systems.

ConcrEITS: An Electrical Impedance Interrogator for Concrete Damage Detection Using Self-Sensing Repairs

Concrete infrastructure requires continuous monitoring to ensure any new damage or repair failures are detected promptly. A cost-effective combination of monitoring and maintenance would be highly beneficial in the rehabilitation of existing infrastructure. Alkali-activated materials have been used as concrete repairs and as sensing elements for temperature, moisture, and chlorides. However, damage detection using self-sensing repairs has yet to be demonstrated, and commercial interrogation solutions are expensive. Here, we present the design of a low-cost tomographic impedance interrogator, denoted the “ConcrEITS”, capable of crack detection and location in concrete using conductive repair patches. Results show that for pure material blocks ConcrEITS is capable of measuring 4-probe impedance with a root mean square error of ±5.4% when compared to a commercially available device. For tomographic measurements, ConcrEITS is able to detect and locate cracks in patches adhered to small concrete beam samples undergoing 4-point bending. In all six samples tested, crack locations were clearly identified by the contour images gained from tomographic reconstruction. Overall, this system shows promise as a cost-effective combined solution for monitoring and maintenance of concrete infrastructure. We believe further up-scaled testing should follow this research before implementing the technology in a field trial.

Fly Ash-Based Eco-Efficient Concretes: A Comprehensive Review of the Short-Term Properties

Development of sustainable concrete as an alternative to conventional concrete helps in reducing carbon dioxide footprint associated with the use of cement and disposal of waste materials in landfill. One way to achieve that is the use of fly ash (FA) as an alternative to ordinary Portland cement (OPC) because FA is a pozzolanic material and has a high amount of alumina and silica content. Because of its excellent mechanical properties, several studies have been conducted to investigate the use of alkali-activated FA-based concrete as an alternative to conventional concrete. FA, as an industrial by-product, occupies land, thereby causing environmental pollution and health problems. FA-based concrete has numerous advantages, such as it has early strength gaining, it uses low natural resources, and it can be configurated into different structural elements. This study initially presents a review of the classifications, sources, chemical composition, curing regimes and clean production of FA. Then, physical, fresh, and mechanical properties of FA-based concretes are studied. This review helps in better understanding of the behavior of FA-based concrete as a sustainable and eco-friendly material used in construction and building industries.

Influence of the Precursor, Molarity and Temperature on the Rheology and Structural Buildup of Alkali-Activated Materials

This study presents an investigation of the effects of the precursor, alkalinity and temperature on the rheology and structural buildup of alkali activated materials. Here, 100% fly ash, 100% slag and blended mixes of fly ash and slag were activated by 4 M, 6 M, 8 M or 10 M (only for sodium hydroxide) solutions at 25 °C, 35 °C, 45 °C and 55 °C. The rheological properties were investigated to obtain the flow curves, viscosity, storage modulus, and loss factor of these materials. The results showed that for the presence of slag, a higher molarity of the alkali activating solution and a high temperature all caused greater interparticle force, leading to an increase in the shear stress and viscosity of the alkali activated materials. It was also observed that slag had the greatest effect on the increase in the storage modulus of the blended mixes. Furthermore, the higher alkalinity and temperature levels were instrumental in initiating the dissolution of fly ash and improving its rate of structural buildup. Moreover, the interdependence of various factors showed that the type of precursor, as well as the concentration of alkali activating solution, were the primary influencing factors on the polymerization process, as well as the rheological measurements of alkali-activated materials.

Eco-House Prototype Constructed with Alkali-Activated Blocks: Material Production, Characterization, Design, Construction, and Environmental Impact

The interest of the construction industry in alkali-activated materials has increased to the extent that these materials are recognized as alternatives to ordinary Portland cement-based materials in the quest for sustainable construction. This article presents the design and construction of a prototype of an eco-friendly house built from concrete blocks produced using alkali activation technology or geopolymerization. The prototype meets the requirements of the current Colombian Regulations for Earthquake Resistant Buildings (NSR-10) and includes standards related to the performance of the materials, design, and construction method for earthquake-resistant confined masonry of one- or two-story buildings. The alkali-activated blocks were obtained from different precursors (aluminosilicates), including a natural volcanic pozzolan, ground granulated blast furnace slag, fly ash, construction and demolition waste (concrete, ceramic, brick, and mortar), and red clay brick waste. The physical-mechanical characterization of the alkali-activated blocks allowed their classification according to the structural specifications of the Colombian Technical Standard NTC 4026 (equivalent to ASTM C90). The global warming potential (GWP) or “carbon footprint” attributed to the raw materials of alkali-activated blocks was lower (25.4–54.7%) than that of the reference blocks (ordinary Portland cement concrete blocks). These results demonstrate the potential of alkali-activated materials for application in the construction of eco-friendly houses.

A Study on Initial Setting and Modulus of Elasticity of AAM Mortar Mixed with CSA Expansive Additive Using Ultrasonic Pulse Velocity

This study investigated the hardening process of alkali-activated material (AAM) mortar using calcium sulfoalumiante (CSA) expansive additive (CSA EA), which accelerates the initial reactivity of AAMs, and subsequent changes in ultrasonic pulse velocity (UPV). After the AAM mortar was mixed with three different contents of CSA EA, the setting and modulus of elasticity of the mortar at one day of age, which represent curing steps, were measured. In addition, UPV was used to analyze each curing step. The initial and final setting times of the AAM mortar could be predicted by analyzing the UPV results measured for 14 h. In addition, the dynamic modulus of elasticity calculated using the UPV results for 24 h showed a tendency similar to that of the static modulus of elasticity. The test results showed that the use of CSA EA accelerated the setting of the AAM mortar and increased the modulus of elasticity, and these results could be inferred using UPV. The proposed measurement method can be effective in evaluating the properties of a material that accelerates the initial reactivity.

Low-Carbon Concrete Based on Binary Biomass Ash-Silica Fume Binder to Produce Eco-Friendly Paving Blocks

The civil construction industry consumes huge amounts of raw materials and energy, especially infrastructure. Thus, the use of eco-friendly materials is indispensable to promote sustainable development. In this context, the present work investigated low-carbon concrete to produce eco-friendly paving blocks. The binder was defined according to two approaches. In the first, a binary binder developed with eucalyptus biomass ash (EBA) and silica fume (SF) was used, in total replacement for Portland cement. In the second, the mixture of residues was used as a precursor in alkali-activation reactions, forming alkali-activated binder. The experimental approach was carried out using five different mixtures, obtained by varying the amount of water or sodium hydroxide solution. The characterization of this new material was carried out using compressive strength, expandability, water absorption, deep abrasion, microstructural investigation, and organic matter degradation potential. The results showed that the EBA-SF system has a performance compatible with Portland cement when used as an alternative binder, in addition to functioning as a precursor to alkali-activated concrete. The blocks produced degraded organic matter, and this degradation is more intense with the incidence of UV. In this way, the EBA-SF binder can be successfully used for the manufacture of ecological paving blocks with low carbon emissions.

Mechanical Properties, Microstructure, and Chloride Content of Alkali-Activated Fly Ash Paste Made with Sea Water

The aim of the present study is to investigate the potential of sea water as a feasible alternative to produce alkali-activated fly ash material. The alkali-activated fly ash binder was fabricated by employing conventional pure water, tap water, and sea water based alkali activating solution. The characteristics of alkali-activated materials were examined by employing compressive strength, mercury intrusion porosimetry, XRD, FT-IR, and ²⁹Si NMR along with ion chromatography for chloride immobilization. The results provided new insights demonstrating that sea water can be effectively used to produce alkali activated fly ash material. The presence of chloride in sea water contributed to increase compressive strength, refine microstructure, and mineralogical characteristics. Furthermore, a higher degree of polymerization on the sea water-based sample was observed by FT-IR and ²⁹Si NMR analysis. However, the higher amount of free chloride ion even after immobilization in sea water-based alkali-activated material, should be considered before application in reinforced structural elements.

Experimental Study on the Shrinkage Behavior and Mechanical Properties of AAM Mortar Mixed with CSA Expansive Additive

In this study, a calcium sulfoaluminate-based expansive additive (0%, 2.5%, 5.0%, and 7.5% by the mass of the binder) was added to compensate for the shrinkage of alkali-activated material (AAM) mortar. Modulus of elasticity curves based on the ACI 209 model were derived for the AAM mortar mixed with the additive by measuring the compressive strength and modulus of elasticity. Moreover, autogenous shrinkage and total shrinkage were measured for 150 days, and drying shrinkage was calculated by excluding autogenous shrinkage from total shrinkage. For the autogenous and drying shrinkage of AAM mortar, shrinkage curves by age were obtained by deriving material constants using the exponential function model. Finally, shrinkage stress was calculated using the modulus of elasticity of the AAM mortar and the curves obtained using the shrinkage model. The results showed that the calcium sulfoaluminate-based expansive additive had an excellent compensation effect on the drying shrinkage of AAM mortar, but the effect was observed only at early ages when the modulus of elasticity was low. From a long-term perspective, the shrinkage compensation effect was low when the modulus of elasticity was high, and thus, shrinkage stress could not be reduced.