The Influence of the Addition of Basalt Powder on the Properties of Foamed Geopolymers

Geopolymers are binder materials that are produced by a chemical reaction between silica or aluminum compounds with an alkaline activating solution. Foamed geopolymer materials are increasingly being cited as a viable alternative to popular organic insulation materials. Since the foaming process of geopolymers is difficult to control, and any achievements in improving the performance of such materials are extremely beneficial, this paper presents the effect of the addition of basalt powder on the properties of foamed geopolymers. This paper presents the results of physicochemical studies of fly ash and basalt, as well as mechanical properties, thermal properties, and structure analysis of the finished foams. The scope of the tests included density tests, compressive strength tests, tests of the thermal conductivity coefficient using a plating apparatus, as well as microstructure tests through observations using light and scanning microscopy. Ground basalt was introduced in amounts ranging from 0 to 20% by mass. It was observed that the addition of basalt powder contributes to a reduction in and spheroidization of pores, which directly affect the density and pore morphology of the materials tested. The highest density of 357.3 kg/m3 was characterized by samples with a 5 wt.% basalt powder addition. Their density was 14% higher than the reference sample without basalt powder addition. Samples with 20 wt.% basalt addition had the lowest density, and the density averaged 307.4 kg/m3. Additionally, for the sample containing 5 wt.% basalt powder, the compressive strength exceeded 1.4 MPa, and the thermal conductivity coefficient was 0.1108 W/m × K. The effect of basalt powder in geopolymer foams can vary depending on many factors, such as its chemical composition, grain size, content, and physical properties. The addition of basalt above 10% causes a decrease in the significant properties of the geopolymer.

Waste Glass Upcycling Supported by Alkali Activation: An Overview

Alkali-activated materials are gaining much interest due to their outstanding performance, including their great resistance to chemical corrosion, good thermal characteristics, and ability to valorise industrial waste materials. Reusing waste glasses in creating alkali-activated materials appears to be a viable option for more effective solid waste utilisation and lower-cost products. However, very little research has been conducted on the suitability of waste glass as a prime precursor for alkali activation. This study examines the reuse of seven different types of waste glasses in the creation of geopolymeric and cementitious concretes as sustainable building materials, focusing in particular on how using waste glasses as the raw material in alkali-activated materials affects the durability, microstructures, hydration products, and fresh and hardened properties in comparison with using traditional raw materials. The impacts of several vital parameters, including the employment of a chemical activator, gel formation, post-fabrication curing procedures, and the distribution of source materials, are carefully considered. This review will offer insight into an in-depth understanding of the manufacturing and performance in promising applications of alkali-activated waste glass in light of future uses. The current study aims to provide a contemporary review of the chemical and structural properties of glasses and the state of research on the utilisation of waste glasses in the creation of alkali-activated materials.

Properties, Microstructure Development and Life Cycle Assessment of Alkali-Activated Materials Containing Steel Slag under Different Alkali Equivalents

To improve solid waste resource utilization and environmental sustainability, an alkali-activated material (AAM) was prepared using steel slag (SS), fly ash, blast furnace slag and alkali activators in this work. The evolutions of SS content (10-50%) and alkali equivalent (4.0-8.0%) on workability, mechanical strength and environmental indicators of the AAM were investigated. Furthermore, scanning electron microscopy, X-ray diffraction and nuclear magnetic resonance techniques were adopted to characterize micromorphology, reaction products and pore structure, and the reaction mechanism was summarized. Results showed that the paste fluidity and setting time gradually increased with the increase in SS content. The highest compressive strength was obtained for the paste at 8.0% alkali equivalent due to the improved reaction rate and process, but it also increased the risk of cracking. However, SS was able to exert a microaggregate filling effect, where SS particles filling the pores increased the structural compactness and hindered crack development. Based on the optimal compressive strength, global warming, abiotic resource depletion, acidification and eutrophication potential of the paste are reduced by 76.7%, 53.0%, 51.6%, and 48.9%, respectively, compared with cement. This work is beneficial to further improve the utilization of solid waste resources and expand the application of environmentally friendly AAMs in the field of construction engineering.

Out-of-plane performance of structurally and energy retrofitted masonry walls: geopolymer versus cement-based textile-reinforced mortar combined with thermal insulation

This paper examines the out-of-plane performance of masonry walls (representative of infills in reinforced concrete frames) which have been upgraded with an outer skin of integrated structural and an energy retrofitting system. The benefits of such an integrated system are mainly cost-related. Nevertheless, before moving to full-scale applications, additional benefits to the structural performance need to be investigated. In this study, the examined configurations of this composite system comprised either thermal insulation boards bonded directly to the wall followed by layers of textile-reinforced mortar (TRM), or thermal insulation boards bonded in-between two TRM layers. Other than the retrofitting layers configuration, the following parameters were also investigated: a) the binder type (cement-based versus geopolymer-based mortars), and b) the textile type (open mesh glass fibre textile versus basalt fibre textile). The results of this experimental study are discussed in terms of failure modes, post-cracking stiffness and ultimate capacities. Overall, this study highlights the mechanical benefits of the TRM plus thermal insulation system while providing insights on the bond performance between the different materials selected. An important finding is that the integrated system is even more effective than a standard TRM application. Finally, the geopolymer mortar seems to be equivalent in terms of performance to the commercially available cement-based mortars.

Alkali-Activated Materials Doped with ZnO: Physicomechanical and Antibacterial Properties

The requirements related to reducing the carbon footprint of cement production have directed the attention of researchers to the use of waste materials such as blast-furnace slag or fly ashes, either as a partial replacement for cement clinker or in the form of new alternative binders. This paper presents alkali-activated materials (AAMs) based on blast-furnace slag partially replaced with fly ash, metakaolin, or zeolite, activated with water glass or water glass with a small amount of water, and doped with zinc oxide. The mortars were tested for flow, hydration heat, mechanical strength, microstructure, and antimicrobial activity. The obtained test results indicate the benefits of adding water, affecting the fluidity and generating a less porous microstructure; however, the tested hydration heat, strength, and antibacterial properties are related to more favorable properties in AAMs produced on water glass alone.

New Experimental Evidence for Drying Shrinkage of Alkali-Activated Slag with Sodium Hydroxide

Alkali-activated slag (AAS) is emerging as a possible and more sustainable alternative to Ordinary Portland Cement (OPC) in the construction industry, thanks to its good mechanical and chemical properties. Conversely, the effects of its high drying shrinkage are still a concern for its long-term durability. This study aims to investigate the drying shrinkage behaviour of six AAS/sodium hydroxide mortar compositions and the main phenomena affecting their drying shrinkage behaviour. Specifically, the molarity, solution-to-binder ratio (s/b), autogenous shrinkage, creep compliance, microcracking, and carbonation are considered as possible causes of the differences between AAS and OPC. The results show that it is not possible to correlate the shrinkage magnitude with the molarity of the activating solution, while an increase in the s/b increases the drying shrinkage. Concerning the other factors, autogenous deformation remains significant even after a period of 112 days, while the creep compliance is definitely affected by the drying process but does not seem to affect the shrinkage magnitude. Furthermore, the presence of microcracks caused by the drying process definitely influences the drying shrinkage. Finally, carbonation depends on the molarity of the activating solution, even though its effects on the material are still unclear.

Synthesis and Characterization of Eco-Efficient Alkali-Activated Composites with Self-Cleaning Properties for Sustainable Construction

In this research, we aimed to design an eco-efficient composite based on alkali-activated materials (AAMs) with self-cleaning properties for sustainable construction. Significant emphasis was placed on determining the role of the type of precursor, the amount of sodium silicate, and the addition of titanium dioxide on the rheological and mechanical properties of AAMs. An important aspect of the research was the modification of AAM with titanium dioxide to obtain the self-cleaning properties. Titanium dioxide, thanks to its photocatalytic properties, enables the reduction of organic pollutants and nitrogen oxides in the urban atmosphere and promotes the cleaning of material surfaces. Blast furnace slag (BFS) was used as the source material, which was then substituted in subsequent formulations with metakaolinite at 50% and fly ash and zeolite at 30%. The best-activated AAMs, in which blast furnace slag and its mixture with metakaolinite were used as precursors, achieved compressive strengths of 50 MPa. BFS mixtures with pozzolans were more difficult to polymerize, although their final strengths were still relatively high, in the range of 33-37 MPa. Adding titanium dioxide (T) improved the final strengths and slightly lowered the heat of hydration and spreading of the AAM mortars. The best self-cleaning properties were achieved with composites that comprised a mixture of blast furnace slag, fly ash, and 2% titanium dioxide.

Production and Incorporation of Calcium-Hydrolyzed Nanoparticles in Alkali-Activated Mine Tailings

This work presented the production and incorporation of calcium-hydrolyzed nano-solutions at three concentrations (1, 2, and 3 wt.%) in alkali-activated gold mine tailings (MTs) from Arequipa, Perú. As the primary activator solution, a sodium hydroxide (NaOH) solution at 10 M was used. Calcium-hydrolyzed nanoparticles with a particle size of 10 nm were localized inside self-assembled molecular spherical systems (micelles) with diameters of less than 80 nm that were well-dispersed in aqueous solutions and acted as secondary activator, and also as additional calcium resource for alkali-activated materials (AAMs) based on low-calcium gold MTs. High-resolution transmission electron microscopy/energy-dispersive X-ray spectroscopy (HR-TEM/EDS) analyses were carried out to characterize the morphology, size, and structure of the calcium-hydrolyzed nanoparticles. Fourier transform infrared (FTIR) analyses were then used to understand the chemical bonding interactions in the calcium-hydrolyzed nanoparticles and in the AAMs. Scanning electron microscopy/energy-dispersive X-ray spectroscopy (SEM/EDS) and quantitative X-ray diffraction (QXRD) were performed to study the structural, chemical, and phase compositions of the AAMs; uniaxial compressive tests evaluated the compressive strength of the reaction AAMs; and nitrogen adsorption-desorption analyses measured porosity changes in the AAMs at the nanostructure level. The results indicated that the main cementing product generated was amorphous binder gel with low quantities of nanostructured C-S-H and C-A-S-H phases. The surplus production of this amorphous binder gel produced denser AAMs at the micro-level and nano-level (macroporous systems). In addition, each increase in the concentration of calcium-hydrolyzed nano-solution had a direct/proportional effect on the mechanical properties of the AAM samples. AAM with 3 wt.% calcium-hydrolyzed nano-solution had the highest compressive strength, with a value of 15.16 MPa, which represented an increase of 62% compared with the original system without nanoparticles that were aged under the same conditions at 70 °C for seven days. These results provided useful information about the positive effect of calcium-hydrolyzed nanoparticles on gold MTs and their conversion into sustainable building materials through alkali activation.

Prediction Model Based on DoE and FTIR Data to Control Fast Setting and Early Shrinkage of Alkaline-Activated Slag/Silica Fume Blended Cementitious Material

This study aims to develop a material-saving performance prediction model for fast-hardening alkali-activated slag/silica fume blended pastes. The hydration process in the early stage and the microstructural properties after 24 h were analyzed using design of experiments (DoE). The experimental results show that the curing time and the FTIR wavenumber of the Si-O-T (T = Al, Si) bond in the band range of 900-1000 cm^-1 after 24 h can be predicted accurately. In detailed investigations, low wavenumbers from FTIR analysis were found to correlate with reduced shrinkage. The activator exerts a quadratic and not a silica modulus-related conditioned linear influence on the performance properties. Consequently, the prediction model based on FTIR measurements proved to be suitable in evaluation tests for predicting the material properties of those binders in the building chemistry sector.

Chloride Transport and Related Influencing Factors of Alkali-Activated Materials: A Review

Chloride transport is a vital issue in the research on the durability of alkali-activated materials (AAMs). Nevertheless, due to its miscellaneous types, complex mix proportions, and limitations in testing methods, the reports of different studies are numerous and vary greatly. Therefore, in order to promote the application and development of AAMs in chloride environments, this work systematically reviews the chloride transport behavior and mechanism, solidification of chloride, influencing factors, and test method of chloride transport of AAMs, along with conclusions regarding instructive insights to the chloride transport problem of AAMs in future work.

Effects of Waste Glass Powder on Rheological and Mechanical Properties of Calcium Carbide Residue Alkali-Activated Composite Cementitious Materials System

As a municipal solid waste, waste glass undergoes pozzolanic activity when ground to a certain fineness. In this paper, calcium carbide residue (CCR) and Na₂CO₃ were used as composite alkali activators for a glass powder-based composite cementitious system. A total of 60% fly ash (FA) and 40% ground granulated blast furnace slag (GGBS) were used as the reference group of the composite cementitious material system, and the effects of 5%, 10%, 15%, and 20% glass powder (GP) replacing FA on the rheological behavior, mechanical properties, and microstructure of alkali-activated composite cementitious systems were investigated. The results showed that with the increase in GP replacing FA, the fluidity of the alkali-activated materials gradually decreased, the shear stress and the equivalent plastic viscosity both showed an increasing trend, and the paste gradually changed from shear thinning to shear thickening. Compared with the reference sample, the fluidity of the alkali-activated material paste with a 20% GP replacement of FA was reduced by 15.3%, the yield shear stress was increased by 49.6%, and the equivalent plastic viscosity was elevated by 32.1%. For the 28d alkali-activated material pastes, the compressive strength and flexural strength were increased by 13% and 20.3%, respectively. The microstructure analysis showed the substitution of FA by GP promoted the alkali-activated reaction to a certain extent, and more C-A-S-H gel was formed.

Recent Advances in Alkali-Activated Materials with Seawater and Sea Sand

The development of sustainable cementitious materials is essential and urgent for the construction industry. Benefiting from excellent engineering properties and a reduced greenhouse gas footprint, alkali-activated materials (AAM) are among the robust alternatives to Portland cement for civil infrastructure. Meanwhile, concrete production also accounts for around 20% of all industrial water consumption, and the global freshwater shortage is increasing. This review discusses recent investigations on seawater-mixed AAMs, including the effects of seawater on workability, reaction mechanism, shrinkage, short and long-term strength, binding of chloride and corrosion of steel reinforcement. Attention is also paid to the utilization of sea sand as aggregate, as well as discussions on the challenges and further research perspectives on the field application of AAMs with seawater and sea sand.

Efficient Co-Valorization of Phosphogypsum and Red Mud for Synthesis of Alkali-Activated Materials

Phosphogypsum and red mud are bulk industrial solid wastes that trigger local environmental problems. In the present investigation, an efficient valorization process was developed through which phosphogypsum and red mud can be transformed into a precursor for the synthesis of high-strength, alkali-activated materials with a seawater-bearing sodium silicate solution as the alkaline activator. The effects of the activator modulus and liquid-to-solid ratio on the strength evolution of the synthesized AAMs as well as the microstructure and chemistry of the reaction products were investigated. The results showed that mineral reconstruction between PG and RM took place during calcination at 950 °C, forming ye'elimite, anhydrite and gehlenite, which then took part in the alkali-activation process and generated thenardite and C-A-S-H gel. The mechanical properties of the synthesized AAMs, ranging from 12.9 MPa to 40.6 MPa, were determined with the activator modulus and liquid-to-solid ratio. Results from the present investigation contributed to the facile and efficient valorization of phosphogypsum and red mud into cementitious construction materials.

Carbonation of Alkali-Activated Materials: A Review

This paper presents a literature review on the effects of accelerated carbonation on alkali-activated materials. It attempts to provide a greater understanding of the influence of CO₂ curing on the chemical and physical properties of various types of alkali-activated binders used in pastes, mortars, and concrete. Several aspects related to changes in chemistry and mineralogy have been carefully identified and discussed, including depth of CO₂ interaction, sequestration, reactions with calcium-based phases (e.g., calcium hydroxide and calcium silicate hydrates and calcium aluminosilicate hydrates), as well as other aspects related to the chemical composition of alkali-activated materials. Emphasis has also been given to physical alterations such as volumetric changes, density, porosity, and other microstructural properties caused by induced carbonation. Moreover, this paper reviews the influence of the accelerated carbonation curing method on the strength development of alkali-activated materials, which has been awarded little attention considering its potential. This curing technique was found to contribute to the strength development mainly through decalcification of the Ca phases existing in the alkali-activated precursor, leading to the formation of CaCO₃, which leads to microstructural densification. Interestingly, this curing method seems to have much to offer in terms of mechanical performance, making it an attractive curing solution that can compensate for the loss in performance caused by less efficient alkali-activated binders replacing Portland cement. Optimising the application of such CO₂-based curing methods for each of the potential alkali-activated binders is recommended for future studies for maximum microstructural improvement, and thus mechanical enhancement, to make some of the "low-performing binders" adequate Portland cement substitutes.

Optimising the Performance of CO2-Cured Alkali-Activated Aluminosilicate Industrial By-Products as Precursors

Three industrial aluminosilicate wastes were studied as precursors to produce alkali-activated concrete: (i) electric arc furnace slag, (ii) municipal solid waste incineration bottom ashes, and (iii) waste glass rejects. These were characterized via X-ray diffraction and fluorescence, laser particle size distribution, thermogravimetric, and Fourier-transform infrared analyses. Distinctive combinations of anhydrous sodium hydroxide and sodium silicate solution were tried by varying the Na₂O/binder ratio (8%, 10%, 12%, 14%) and SiO₂/Na₂O ratio (0, 0.5, 1.0, 1.5) to find the optimum solution for maximized mechanical performance. Specimens were produced and subjected to a three-step curing process: (1) 24 h thermal curing (70 °C), (2) followed by 21 days of dry curing in a climatic chamber (~21 °C, 65% RH), and (3) ending with a 7-day carbonation curing stage (5 ± 0.2% CO₂; 65 ± 10% RH). Compressive and flexural strength tests were performed, to ascertain the mix with the best mechanical performance. The precursors showed reasonable bonding capabilities, thus suggesting some reactivity when alkali-activated due to the presence of amorphous phases. Mixes with slag and glass showed compressive strengths of almost 40 MPa. Most mixes required a higher Na₂O/binder ratio for maximized performance, even though, contrary to expectations, the opposite was observed for the SiO₂/Na₂O ratio.

Alumino-Silicate Structural Formation during Alkali-Activation of Metakaolin: In-Situ and Ex-Situ ATR-FTIR Studies

Attenuated total reflectance-Fourier transform infrared (ATR-FTIR) spectroscopy was used to demonstrate the reaction mechanisms of alkali-activated materials (AAMs) and the early stage of structure formation in the materials. The effects of different types of alkali activator solutions on the structure formation and reaction mechanisms of AAMs were studied. The results revealed that the main peaks of the ATR-FTIR spectra of the AAMs in the 1300-650 cm^-1 range shifted to a low wavenumber with changing patterns, depending on the activator solution used, indicating that the dissolution and reorientation of metakaolin had occurred. Silica and alumina monomers were dissolved by the NaOH solution to produce crystalline zeolites. Although the reaction between metakaolin and Na₂SiO₃ solution is slow, the condensation between the Al-OH from metakaolin and the Si-OH from Na₂SiO₃ solution bonded the chain to be longer. Therefore, the Na₂SiO₃ solution acted as a template-bonded monomer, formed long chains of Si-O-Si and Si-O-Al, and produced an amorphous AAM structure. In the mixed solution, when the NaOH in it dissolved the Si and Al monomers, the Na₂SiO₃ in the solution also bonded with monomers and produced a complex structure. The different reaction that metakaolin had with different alkali activator solutions reflected the different phases, microstructures, and mechanical properties of the AAMs produced.

Effect of Solution-to-Binder Ratio and Alkalinity on Setting and Early-Age Properties of Alkali-Activated Slag-Fly Ash Binders

The growing use of blends of low- and high-calcium solid precursors in combination with different alkaline activators requires simple, efficient, and accurate experimental means to characterize their behavior, particularly during the liquid-to-solid transition (setting) at early material ages. This research investigates slag-fly ash systems mixed at different solution-to-binder (s/b) ratios with sodium silicate/sodium hydroxide-based activator solutions of varying concentrations. Therefore, continuous non-destructive tests-namely ultrasonic pulse velocity (UPV) measurements and isothermal calorimetry tests-are combined with classical slump flow, Vicat, and uniaxial compressive strength tests. The experimental results highlight that high alkali and silica contents and a low s/b ratio benefit the early-age hydration, lead to a faster setting, and improve the early-age strength. The loss of workability, determined from the time when the slump flow becomes negligible, correlates well with ultrasonic P-wave velocity evolutions. This is, however, not the case for Vicat or calorimetry tests.

Influence of Various Coal Energy Wastes and Foaming Agents on Foamed Geopolymer Materials' Synthesis

The regularities of obtaining foamed alkali-activated geopolymer materials based on different wastes of coal power engineering (fly ash, fuel (boiler) slag, ash, and slag mixture) were considered. The phase composition of the studied waste showed the presence of a significant amount of the amorphous phase, as well as a crystalline phase. mostly in the form of high quartz. The microstructure of studied the waste showed that the fly ash consisted of monodisperse hollow aluminosilicate microspheres, the fuel slag was represented by polydisperse irregular particles, and the ash and slag mixture included both of these materials in different ratios. Blowing agents such as aluminum powder, hydrogen peroxide, and sodium hypochlorite were chosen to achieve the porous structure of the geopolymer materials. The calculations of the geopolymer precursor compositions were carried out. Samples were synthesized, and their physical and mechanical properties, such as density, strength, porosity, and thermal conductivity, were analyzed. The micro- and macrostructure of the samples, as well as the pore distribution of the obtained geopolymers were studied. Conclusions were made on the choice of the most-optimal foaming agent and the optimal coal combustion waste suitable for the synthesis of the geopolymer materials.

Effects of Na2CO3/Na2SiO3 Ratio and Curing Temperature on the Structure Formation of Alkali-Activated High-Carbon Biomass Fly Ash Pastes

This study explored unprocessed high-carbon biomass fly ash (BFA) in alkali-activated materials (AAM) with less alkaline Na₂CO₃ as the activator. In this paper, the effects of the Na₂CO₃/Na₂SiO₃ (C/S) ratio and curing temperature (40 °C and 20 °C) on the setting time, structure formation, product synthesis, and physical-mechanical properties of alkali-activated BFA pastes were systematically investigated. Regardless of curing temperature, increasing the C/S ratio increased the density and compressive strength of the sample while a decrease in water absorption. The higher the curing temperature, the faster the structure evolution during the BFA-based alkaline activation synthesis process and the higher the sample's compressive strength. According to XRD and TG/DTA analyses, the synthesis of gaylussite and C-S-H were observed in the sample with an increasing C/S ratio. The formation of the mentioned minerals contributes to the compressive strength growth of alkali-activated BFA pastes with higher C/S ratios. The findings of this study contribute to the applicability of difficult-to-recycle waste materials such as BFA and the development of sustainable BFA-based AAM.

Valorization of Fly Ashes and Sands Wastes from Biomass Boilers in One-Part Geopolymers

Fly ash (FA) and exhausted bed sands (sands wastes) that are generated in biomass burners for energy production are two of the wastes generated in the pulp and paper industry. The worldwide production of FA biomass is estimated at 10 million tons/year and is expected to increase. In this context, the present work aims to develop one-part alkali-activated materials with biomass FA (0–100 wt.% of the binder) and sands wastes (100 wt.% of the aggregate). FA from two different boilers, CA and CT, was characterized and the mortar’s properties, in the fresh and hardened conditions, were evaluated. Overall, the incorporation of FA decreases the compressive strength of the specimens. However, values higher than 30 MPa are reached with 50 wt.% of FA incorporation. For CA and CT, the compressive strength of mortars with 28 days of curing was 59.2 MPa (0 wt.%), 56.9 and 57.0 MPa (25 wt.%), 34.9 and 46.8 MPa (50 wt.%), 20.5 and 13.5 MPa (75 wt.%), and 9.2 and 0.2 MPa (100 wt.%), respectively. The other evaluated characteristics (density, water absorption, leached components and freeze–thaw resistance) showed no significant differences, except for the specimen with 100 wt.% of CA. Therefore, this work proved that one-part geopolymeric materials with up to 90 wt.% of pulp and paper industrial residues (FA and sand) can be produced, thus reducing the carbon footprint associated with the construction sector.

Geopolymer: A Systematic Review of Methodologies

The geopolymer concept has gained wide international attention during the last two decades and is now seen as a potential alternative to ordinary Portland cement; however, before full implementation in the national and international standards, the geopolymer concept requires clarity on the commonly used definitions and mix design methodologies. The lack of a common definition and methodology has led to inconsistency and confusion across disciplines. This review aims to clarify the most existing geopolymer definitions and the diverse procedures on geopolymer methodologies to attain a good understanding of both the unary and binary geopolymer systems. This review puts into perspective the most crucial facets to facilitate the sustainable development and adoption of geopolymer design standards. A systematic review protocol was developed based on the Preferred Reporting of Items for Systematic Reviews and Meta-Analyses (PRISMA) checklist and applied to the Scopus database to retrieve articles. Geopolymer is a product of a polycondensation reaction that yields a three-dimensional tecto-aluminosilicate matrix. Compared to unary geopolymer systems, binary geopolymer systems contain complex hydrated gel structures and polymerized networks that influence workability, strength, and durability. The optimum utilization of high calcium industrial by-products such as ground granulated blast furnace slag, Class-C fly ash, and phosphogypsum in unary or binary geopolymer systems give C-S-H or C-A-S-H gels with dense polymerized networks that enhance strength gains and setting times. As there is no geopolymer mix design standard, most geopolymer mix designs apply the trial-and-error approach, and a few apply the Taguchi approach, particle packing fraction method, and response surface methodology. The adopted mix designs require the optimization of certain mixture variables whilst keeping constant other nominal material factors. The production of NaOH gives less CO₂ emission compared to Na₂SiO_3, which requires higher calcination temperatures for Na₂CO₃ and SiO_2. However, their usage is considered unsustainable due to their caustic nature, high energy demand, and cost. Besides the blending of fly ash with other industrial by-products, phosphogypsum also has the potential for use as an ingredient in blended geopolymer systems. The parameters identified in this review can help foster the robust adoption of geopolymer as a potential "go-to" alternative to ordinary Portland cement for construction. Furthermore, the proposed future research areas will help address the various innovation gaps observed in current literature with a view of the environment and society.

Influence Factors in the Wide Application of Alkali-Activated Materials: A Critical Review about Efflorescence

Applications related to alkali-activated materials (AAMs) have received much attention due to their excellent mechanical properties and low-energy production. Although much research has focused on developing AAMs, their application is still limited. One of the primary reasons is the efflorescence. Not only does efflorescence affect the material aesthetics, but it also affects the mechanical performance, leading to a decrease in material quality. This paper first summarizes the current research on AAMs efflorescence. The formation process of efflorescence is divided into three parts: alkaline cation leaching, air carbonation, and efflorescence formation. Furthermore, the influences caused by different factors, including raw materials, curing conditions, AAMs modalities, etc., on the efflorescence are proposed. This paper highlights the solutions for efflorescence by avoiding free alkaline cation leaching and preventing air carbonation. The advantages and disadvantages of efflorescence are discussed in-depth, showing that it can be exploited under certain conditions, such as in wastewater treatment. This paper has important implications for the practical preparation and application of AAMs.

Effect of Ultrafine Fly Ash and Water Glass Content on the Performance of Phosphorus Slag-Based Geopolymer

Phosphorus slag (PS), an industrial waste slag, has been used in geopolymers because it is rich in silicon and calcium. The poor performance of phosphorus slag-based geopolymer is due to its aluminum deficiency. In this work, low-calcium fly ash, treated by a wet-grinding process, named wet-grinding ultrafine fly ash (WUFA) was used as an Al supplement to replace some of the phosphorus slag, and the wet-grinding, ultrafine fly ash-phosphorus slag (WUFA-PS)-based geopolymer was prepared. The effects of the substitution amount of WUFA and the activator dosage on the hydration properties, mechanical properties, pore structure and SEM of the WUFA-PS geopolymer were discussed in detail. The results indicate that WUFA and more activators contribute to the Al and high alkalinity environment, which positively induces the production of more geopolymer gels, thus releasing more heat and optimizing the pore structure of the matrix. The compressive strength increased by up to 28.1%. The enhanced performance of the WUFA-PS-based geopolymer may also arise from the filling effect and activity improvement of WUFA. This study has proved the feasibility of preparing a geopolymer by blending wet-grinding ultrafine fly ash and phosphorus slag and has provided references for the ratio and performance evaluation of WUFA-PS-based geopolymer concrete.

The Effect of the Type of Activator Anion on the Hydration of Ground Granulated Blast Furnace Slag

In this study, ground granulated blast furnace slag was activated with a wide variety of sodium salts to compare the effects of their pH and anion size on the hydration progress and compressive strength development of GGBFS pastes. Research was carried out on samples activated with twelve different sodium salts and cured for one year. Changes in their phase composition (XRD), loss on ignition at different temperatures, expansion and microstructure (SEM + EDS) were examined over the entire curing period. The results showed that the presence of sodium ions is more important than the pH of the system, as activation took place even in the case of compounds whose solutions are characterized by a low pH, such as sodium tartrate or phosphate. The compressive strength of the pastes ranged from approximately 8 to 65 MPa after one year of curing.

Effect of Admixtures on Durability and Physical-Mechanical Properties of Alkali-Activated Materials

The results of ground granulated blast furnace slag (GGBS) tests in alkali-activated systems show that, with its use, it is possible to produce promising materials with the required properties. Unfortunately, GGBS is becoming a scarce commodity on the market, so the effort is to partially replace its volume in these materials with other secondary materials, while maintaining the original properties. This paper focuses on a comparison of two basic types of mixtures. The first mixture was prepared only from ground granulated blast furnace slag (GGBS) and the second type of mixture was prepared with admixtures, where the admixtures formed a total of 30% (15% of the replacement was fly ash after denitrification—FA, and 15% of the replacement was cement by-pass dust—CBPD). These mixtures were prepared with varying amounts of activator and tested. The experiment monitored the development of strength over time and the influence of different types of aggressive environments on the strength characteristics. Thermal analysis and FTIR were used in the experiment to determine the degradation products. The paper provides an interesting comparison of the resistance results of different composites in aggressive environments and at the same time an evaluation of the behavior of individual mixtures in different types of aggressive environment. After 28 days of maturation, the highest strengths were obtained with mixtures with the lowest doses of activator. The difference in these compressive strengths was around 25% in favor of the mixtures with only GGBS; in the case of flexural strength, this difference was around 23%. The largest decreases in strength were achieved in the XA3 environment. This environment contains the highest concentration of sulfate ions according to the EN 206-1 standard. The decreases in compressive strength were 40–45%, compared to the same old reference series. The surface degraded due to sulfate ions. Calcium sulphate dihydrate was identified by FTIR, thermal analysis and SEM as a degradation product.

In-Situ Crystallization and Characteristics of Alkali-Activated Materials-Supported Analcime-C from a By-Product of the Lithium Carbonate Industry

The present study proposes a new process for synthesis of alkali-activated materials (AAM)-supported analcime-C foam materials (AFs), utilizing a by-product of the lithium carbonate industry. This material has great application value as a bulk-type solid adsorbent. Characterization analyses show that the alkaline activator modulus greatly affects the crystallinity of analcime-C in AFs. Furthermore, the compressive strength, zeolite yield, and microstructure of AFs are significantly affected by the saturated steam parameters, including crystallization pressure, temperature, and time. The synthesized materials comprise pores of different sizes (micro to macro). They combine the functional micro-porosity of the analcime-C, the meso-porosity of the gel matrix, and the macro-porosity of the foamed AAM. The maximum compressive strength, density, total porosity, and Pb²⁺ adsorption capacity of AFs investigated in this study are 1.15 MPa, 350 kg/m³, 76.5%, and 69.3 mg/g Pb²⁺, respectively. Unlike many granular adsorbents, the bulk AFs adsorbent produced by this process is easy to recycle. In addition, it also contributes to the comprehensive utilization of a by-product of the lithium carbonate industry.

Impact of Na/Al Ratio on the Extent of Alkali-Activation Reaction: Non-linearity and Diminishing Returns

To address the high CO₂ footprint associated with cement production, many alternative, sustainable binders are now gaining worldwide attention-including alkali-activated materials. The alkali-activation reaction of metakaolin is a fairly complex process involving transformation of one amorphous reactant (precursor metakaolin) into another amorphous product or products (N-A-S-H gel and/or disordered zeolite type phases). In spite of this complexity, researchers in the past 2 decades have gained significant knowledge on the nature of this reaction at multiple scales. Understanding and developing a clear relationship between the alkalinity of the mix and the extent of reaction is of high interest for practical applications. However, detailed and thorough investigations on this important relationship are limited. Here, in this study, we address this gap by systematically investigating a series of alkali-activated materials samples with a wide range of Na/Al ratios (0.5-1.8) using seven different yet complementary analytical techniques (isothermal calorimetry, FTIR, XRD, TGA, NMR, and Raman imaging). Applied in tandem, these tools reveal a clear but non-linear relationship between the Na/Al ratio and the extent of alkali-activation reaction indicating diminishing returns at higher Na/Al ratios, where higher Na/Al ratios cause an increase in the degree of reaction until a certain point at which the increase in Na/Al ratio does not significantly affect the reaction kinetics, but may affect the gel polymerization. These findings could potentially aid decision making for commercial applications of AAMs where alkalinity of the mix is an important parameter for performance as well as safety.

Effects of Composition Type and Activator on Fly Ash-Based Alkali Activated Materials

The compressive strengths of fly ash-based alkali-activated materials (AAM), produced using various activators of only sodium hydroxide, were measured. Fly ash-based AAM specimens, produced by mixing different kinds of fly ash and ground granulated blast-furnace slag (GGBFs) with an activator containing only sodium hydroxide, were cured at ambient temperature, and then placed in air for different numbers of days. The short- and long-term compressive strengths and shrinkage of fly ash-based AAM were measured and compared to one another. The effects of type of fly ash, alkali-equivalent content, GGBFs replace percentage, and ages on the compressive strengths and shrinkage of fly ash-based AAM were investigated. Even when different fly ash was used as the raw material for AAM, a similar compressive strength can be achieved by alkali-equivalent content, GGBFs replaces percentage. However, the performance of shrinkage due to different types of fly ash differed significantly.

The Effect of Gel-Type Contributions in Lime-Sand Bricks, Alkali-Activated Slags and CEMI/CEMIII Pastes: Implications for Next Generation Concretes

Lime-sand bricks of different ages were investigated using IR-spectroscopy, thermogravimetry, and X-ray diffraction/scattering. After subtraction of the dominant quartz contribution (80%), the IR spectra show the absorption peaks of the hydrothermally formed binder phases. The spectra also show the alteration of the binder during ageing under atmospheric conditions by the influence of CO₂ forming carbonate and a condensed SiO₂-gel (secondary gel). The alteration could also be proven in X-ray pattern, obtaining a separation between crystalline CSH and amorphous contributions in the freshly produced lime-sand brick, too. Here, the formation of CSH_amorph could be understood as a precursor state (primary gel) to the crystallization of CSH phases. X-ray patterns of aged bodies of alkali-silicate solution activated slags (AAS), CEM-I/CEM-III pastes, and CEM-I concrete indicate that in all cases a similar amorphous CSH-type phase (CSH_amorph) was formed, which is responsible for the hardening properties as the glue. The main X-ray peak of CSH_amorph obtained using CuK_α-radiation with a usual diffractometer is observed between 24° and 35° 2 Theta with maximum at about 29° 2 Theta, whereas it appears much more broadly distributed between 15° and 35° 2 Theta with maximum between 26° and 28° 2 Theta for a geopolymer body prepared using the reaction of alkali-silicate solution and metakaolin (AAMK). This is due to the network formed by siloxo and sialate units in the case of AAMK, given that any crystallization can be ruled out. The origin of increasing mechanical strength during the ageing of AAS mortars must be due to further crosslinking of the preformed siloxo chains. Thermal treatment up to 800 °C leads to a complete loss of any mechanical strength of the CEM pastes due to the destruction of crystalline CSH-phases, whereas geopolymer bodies maintain their strength. Implications for next generation concrete include that cement clinker could be completely replaced by using a using alkali silcate solution technology for gel formation.

Mine Clay Washing Residues as a Source for Alkali-Activated Binders

The aim of this paper is to promote the use of mine clay washing residues for the preparation of alkali activated materials (AAMs). In particular, the influence of the calcination temperature of the clayey by-product on the geopolymerization process was investigated in terms of chemical stability and durability in water. The halloysitic clay, a mining by-product, has been used after calcination and mixed with an alkaline solution to form alkali activated binders. Attention was focused on the influence of the clay’s calcination treatment (450–500–600 °C) on the geopolymers’ microstructure of samples, remaining in the lower limit indicated by the literature for kaolinite or illite calcination. The mixtures of clay and alkali activators (NaOH 8M and Na-silicate) were cured at room temperature for 28 days. The influence of solid to liquid ratio in the mix formulation was also tested in terms of chemical stability measuring the pH and the ionic conductivity of the eluate after 24-h immersion time in water. The results reported values of ionic conductivity higher for samples made with untreated clay or with low temperature of calcination (≥756 mS/m) compared with values of samples made with calcined clay (292 mS/m). This result suggests that without a proper calcination of the as-received clay it was not possible to obtain 25 °C-consolidated AAMs with good chemical stability and dense microstructure. The measures of integrity test, pH, and ionic conductivity in water confirmed that the best sample is made with calcined clay at 600 °C, being similar (53% higher ionic conductivity of the eluate) or equal (integrity test and pH) to values recorded for the metakaolin-based geopolymer considered the reference material. These results were reflected in term of reticulation and morphology of samples through the analysis with scanning electron microscope (SEM) and X-ray diffraction (XRD), which show a dense and homogeneous microstructure predominantly amorphous with minor amounts of quartz, halloysite, and illite crystalline phases. Special attention was dedicated to this by-product to promote its use, given that kaolinite (and metakaolin), as primary mineral product, has a strong impact on the environment. The results obtained led us to consider this halloysite clay very interesting as an aluminosilicate precursor, and extensively deepening its properties and reactivity for the alkaline activation. In fact, the heart of this work is to study the possibility of reusing this by-product of an industrial process to obtain more sustainable high-performance binders.

Chloride Ions' Penetration of Fly Ash and Ground Granulated Blast Furnace Slags-Based Alkali-Activated Mortars

Due to the need to reduce the CO₂ emissions of mineral binders, researchers are considering the use of alkali-activated materials (AAMs) as an alternative to cementitious binders. The properties of AAMs can be more advantageous than those presented by cementitious binders, and thus they can replace Portland cement binders in some applications. Mechanical tests of AAMs are being conducted on an ongoing basis; however, durability issues related to reinforcing steel in conditions in which steel members interact with chloride ions remain unsolved. In this paper, the precursors for AAM preparations are blends of fly ash (FA) and ground granulated blast-furnace slag (GGBFS) in four slag proportions: 0%, 10%, 30% and 50% expressed as a percent of FA mass. Four alkali-activated mortars were prepared, denominated as AAM 0, AAM 10, AAM 30 and AAM 50, respectively. Their basic physical and mechanical characteristics were investigated, as were their gas transport properties. The nitrogen Cembureau method was applied to determine the permeability of the mortar. The transport properties of the chloride ions were determined using the modified NT BUILD 492 migration test. The comparison of results obtained demonstrated a positive effect of GGBFS addition in terms of an increase in bulk density, permeability, porosity and, at the same time, a reduction in chloride ion penetration. The water absorption tests also provided insight into the open pore structures of mortars. The measurements revealed a strong dependence between fluid transport through the mortars and the water absorption and initial water content of materials.

The Utilization of Alkali-Activated Lead-Zinc Smelting Slag for Chromite Ore Processing Residue Solidification/Stabilization

Lead–zinc smelting slag (LZSS) is regarded as a hazardous waste containing heavy metals that poses a significant threat to the environment. LZSS is rich in aluminosilicate, which has the potential to prepare alkali-activated materials and solidify hazardous waste, realizing hazardous waste cotreatment. In this study, the experiment included two parts; i.e., the preparation of alkali-activated LZSS (pure smelting slag) and chromite ore processing residue (COPR) solidification/stabilization. Single-factor and orthogonal experiments were carried out that aimed to explore the effects of various parameters (alkali solid content, water glass modulus, liquid–solid ratio, and initial curing temperature) for alkali-activated LZSS. Additionally, compressive strength and leaching toxicity were the indexes used to evaluate the performance of the solidified bodies containing COPR. As a result, the highest compressive strength of alkali-activated LZSS reached 84.49 MPa, and when 40% COPR was added, the strength decreased to 1.42 MPa. However, the leaching concentrations of Zn and Cr from all the solidified bodies were far below the critical limits (US EPA Method 1311 and China GB5085.3-2007). Heavy-metal ions in LZSS and COPR were immobilized successfully by chemical and physical means, which was detected by analyses including environmental scanning electron microscopy with energy-dispersive spectrometry, Fourier transform infrared spectrometry, and X-ray diffraction.

The Effect of Fibrous Reinforcement on the Polycondensation Degree of Slag-Based Alkali Activated Composites

Alternative cementitious binders, based on industrial side streams, characterized by a low carbon footprint, are profitably proposed to partially replace Portland cement. Among these alternatives, alkali-activated materials have attracted attention as a promising cementitious binder. In this paper, the chemical stability of the matrix, in fiber-reinforced slag-based alkali-activated composites, was studied, in order to assess any possible effect of the presence of the reinforcement on the chemistry of polycondensation. For this purpose, organic fiber, cellulose, and an inorganic fiber, basalt, were chosen, showing a different behavior in the alkaline media that was used to activate the slag fine powders. The novelty of the paper is the study of consolidation by means of chemical measurements, more than from the mechanical point of view. The evaluation of the chemical behavior of the starting slag in NaOH, indeed, was preparatory to the understanding of the consolidation degree in the alkali-activated composites. The reactivity of alkali-activated composites was studied in water (integrity test, normed leaching test, pH and ionic conductivity), and acids (leaching in acetic acid and HCl attack). The presence of fibers does not favor nor hinder the geopolymerization process, even if an increase in the ionic conductivity in samples containing fibers leads to the hypothesis that samples with fibers are less consolidated, or that fiber dissolution contributes to the conductivity values. The amorphous fraction was enriched in silicon after HCl attack, but the structure was not completely dissolved, and the presence of an amorphous phase is confirmed (C-S-H gel). Basalt fibers partly dissolved in the alkaline environment, leading to the formation of a C-N-A-S-H gel surrounding the fibers. In contrast, cellulose fiber remained stable in both acidic and alkaline conditions.

Geopolymer Foams-Will They Ever Become a Viable Alternative to Popular Insulation Materials?-A Critical Opinion

Over the last several years, there has been a large increase in interest in geopolymer materials, which are usually produced from waste materials, and their applications. The possibilities of application of geopolymers seem to be unlimited, and they are used in almost all fields of technology. Their use as insulation materials appears promising due to their complete nonflammability and excellent strength. However, one limitation is their complex manufacturing process and lack of stability of the obtained geopolymer foams as well as difficulties in achieving such good insulation properties possessed by polyurethane foams, polystyrene, and wool. Hundreds of studies have already been performed on insulating geopolymer foams and various types of foaming agents, and their authors reported that foamed insulating geopolymers had a density starting from 200 kg/m³ and thermal conductivity from 0.04 W/mK. However, the repeatability of the obtained results on an industrial scale is questionable. It is still a challenge to obtain a geopolymer material with comparable properties as conventional insulation materials and to overcome the barriers associated with the successful implementation of geopolymer material as insulation in buildings and other applications on a mass scale. This paper provides a comprehensive review of the methods used for the production of foamed geopolymers and the best parameters obtained, as well as a summary of the most important information reported in the scientific literature. It also presents the results of a critical analysis of the feasibility of implementing this technology for mass deployment. In addition, the problems and limitations that are most often encountered with the implementation of geopolymer technology are discussed.

Deformation of Alkali-Activated Materials at an Early Age Under Different Curing Conditions

The production of alkali-activated materials (AAMs) is known for its environmentally friendly processing method, where several amorphous-rich aluminosilicate material sources combine with an alkali media solution to form solid, ceramic-like materials. In terms of the Si:Al, Na(K):Al, and Na(K):H₂O ratios, the theory of AAM formation is quite well developed, but some open questions in the technology process remain, especially with regards to the means of curing, where the generation of defects can be persistent. Knowing that deformation is extremely high in the early ages, this study investigates the effects of temperature and moisture on shrinkage behavior within the first 72 h of AA pastes made from ladle (LS) and electric arc furnace (EAF) slag and activated by sodium silicate (Na₂SiO₃). The method to determine the deformation of alkali-activated slag-based materials, in terms of both autogenous and drying shrinkage, was based on the modified ASTM C1698-19 standard for the measurement of autogenous shrinkage in cement pastes. Autogenous deformation and strain were measured in four samples, using the standard procedure at room temperature, 40 and 60°C. Furthermore, using an adjusted method, nine samples were characterized for strain and partial surface pressure, while drying at room temperature, 40, or 60°C at a relative humidity of 30 or 90%. The results show that the highest rate of autogenous shrinkage occurred at a temperature of 60°C, followed by drying shrinkage at 60°C and 30% relative humidity, owing to the fact that the rate of evaporation was highest at this moisture content. The study aimed to provide guidance regarding selection of the optimal curing set in order to minimize deformations in slag-based alkali-activated materials. In the present case, curing at a temperature of around 40°C under lower moisture conditions for the first 24 h provided optimal mechanical properties for the slags investigated. The methodology might also be of use for other aluminosilicate sources such as metakaolin, fly ash, and mineral wool–based alkali-activated materials.

Study on the Compressive Strength of Alkali Activated Fly Ash and Slag under the Different Silicate Structure

Due to its high activation efficiency, waterglass has been widely used for alkali activations in geopolymer. In this study, the n(SiO₂)/n(Na₂O) (Ms) of waterglass was selected as the variable to investigate the role of the silicate structure on the mechanical properties of harden pastes. Ms was changed by the addition of NaOH to obtain the different silicate group, structure and experiments were performed by employing the liquid-sate ²⁹Si nuclear magnetic resonance (NMR), Fourier transform infrared spectroscopy (FTIR), dynamic light scattering (DLS) and gel permeation chromatography (GPC) techniques. Furthermore, selected dissolution, scanning electron microscope (SEM-EDX), X-ray photoelectron spectroscopy (XPS) and FTIR experiments were used to measure the development of the amorphous gel and other materials with different curing condition. Results show that silicate structure of the waterglass was changed via the Si-ONa⁺ formation and the electric charge effect of Na⁺. Under the lower Ms waterglass, the Q⁰, Q¹ and Q_C² structure reverted to the main structure of the silicate group, which was kind of lower seize, molecule weight, linear or circular chain lower geopolymerization degree silicon structure. It would accelerate the geopolymerization speed of prepolymer formation. In addition, higher activity degree of Q⁰ and Q¹ were useful to increase the formation amount of the gel structure with a low Si/Al ratio and size. Thus, silicate structure of waterglass controls the amorphous gel properties to adjust the compressive strength of alkali-activated materials.

Role of Curing Conditions and Precursor on the Microstructure and Phase Chemistry of Alkali-Activated Fly Ash and Slag Pastes

Understanding the role of curing conditions on the microstructure and phase chemistry of alkali-activated materials (AAMs) is essential for the evaluation of the long-term performance as well as the optimization of the processing methods for achieving more durable AAMs-based concretes. However, this information cannot be obtained with the common material characterization techniques as they often deliver limited information on the chemical domains and proportions of reaction products. This paper presents the use of PhAse Recognition and Characterization (PARC) software to overcome this obstacle for the first time. A single precursor (ground granulated blast-furnace slag (GBFS)) and a binary precursor (50% GBFS–50% fly ash) alkali-activated paste are investigated. The pastes are prepared and then cured in sealed and unsealed conditions for up to one year. The development of the microstructure and phase chemistry are investigated with PARC, and the obtained results are compared with independent bulk analytical techniques X-ray Powder Fluorescence and X-ray Powder Diffraction. PARC allowed the determination of the type of reaction products and GBFS and FA’s spatial distribution and degree of reaction at different curing ages and conditions. The results showed that the pastes react at different rates with the dominant reaction products of Mg-rich gel around GBFS particles, i.e., Ca-Mg-Na-Al-Si, and with Ca-Na-Al-Si gel, in the bulk paste. The microstructure evolution was significantly affected in the unsealed curing conditions due to the Na⁺ loss. The effect of the curing conditions was more pronounced in the binary system.

Volcanic Ash as a Sustainable Binder Material: An Extensive Review

The construction industry is affected by the constant growth in the populations of urban areas. The demand for cement production has an increasing environmental impact, and there are urgent demands for alternative sustainable solutions. Volcanic ash (VA) is an abundant low-cost material that, because of its chemical composition and amorphous atomic structure, has been considered as a suitable material to replace Portland cement clinker for use as a binder in cement production. In the last decade, there has been interest in using alkali-activated VA material as an alternative material to replace ordinary Portland cement. In this way, a valuable product may be derived from a currently under-utilized material. Additionally, alkali-activated VA-based materials may be suitable for building applications because of their good densification behaviour, mechanical properties and low porosity. This article describes the most relevant findings from researchers around the world on the role of the chemical composition and mineral contents of VA on reactivity during the alkali-activation reaction; the effect of synthesis factors, which include the concentration of the alkaline activator, the solution-to-binder ratio and the curing conditions, on the properties of alkali-activated VA-based materials; and the mechanical performance and durability properties of these materials.

Evaluation of Physical Properties of a Metakaolin-Based Alkali-Activated Binder Containing Waste Foam Glass

Foam glass production process redounds to large quantities of waste that, if not recycled, are stockpiled in the environment. In this work, increasing amounts of waste foam glass were used to produce metakaolin-based alkali-activated composites. Phase composition and morphology were investigated by means of X-ray powder diffraction, Fourier-transform infrared spectroscopy and scanning electron microscopy. Subsequently, the physical properties of the materials (density, porosity, thermal conductivity and mechanical strength) were determined. The analysis showed that waste foam glass functioned as an aggregate, introducing irregular voids in the matrix. The obtained composites were largely porous (>45%), with a thermal conductivity coefficient similar to that of timber (<0.2 W/m∙K). Optimum compressive strength was achieved for 10% incorporation of the waste by weight in the binder. The resulting mechanical properties suggest the suitability of the produced materials for use in thermal insulating applications where high load-bearing capacities are not required. Mechanical or chemical treatment of the waste is recommended for further exploitation of its potential in participating in the alkali activation process.

Carbonation and Chloride Ions' Penetration of Alkali-Activated Materials: A Review

Alkali-activated materials (AAMs) are widely recognized as potential alternatives to ordinary Portland cement (OPC) due to their lower carbon footprint. However, like OPC, AAMs can also generate some durable problems when exposed to aggressive environments and the mechanisms and possible improvements are still not fully clear in existing investigations. Furthermore, the corrosion mechanisms of AAMs are different from OPC due to the discrepant reaction products and pore structures. Thus, this study’s aim is to review the chemical reaction mechanisms, factors, and mitigation methods when AAMs are attacked by carbonation and chloride ions, along with a summative discussion regarding instructive insights to durable problems of AAMs.

Incorporation of Alkali-Activated Municipal Solid Waste Incinerator Bottom Ash in Mortar and Concrete: A Critical Review

In the light of one of the most common waste management issues in urban areas, namely the elimination of municipal solid waste (MSW; about 486 kg of the waste per capita were generated in the EU in 2017), this study discusses one technique as an outlet in the construction industry for the by-product of the waste’s incineration in energy recovery facilities (i.e., MSW incinerator bottom ash—MIBA). There have been some investigations on the use of MIBA as partial replacement of cement to be used in cementitious composites, such as concrete and mortars. However, the waste’s incorporation ratio is limited since further products of hydration may not be produced after a given replacement level and can lead to an unsustainable decline in performance. In order to maximize the incorporation of MIBA, some research studies have been conducted on the alkali activation of the waste as precursor. Thus, this study presents an extensive literature review of the most relevant investigations on the matter to understand the material’s applicability in construction. It analyses the performance of the alkali-activated MIBA as paste, mortar, and concrete from different perspectives. This literature review was made using search engines of several databases. In each database, the same search options were repeated using combinations of various representative keywords. Furthermore, several boundaries were made to find the most relevant studies for further inspection. The main findings of this review have shown that the chemical composition and reactivity of MIBA vary considerably, which may compromise performance comparison, standardization and commercialization. There are several factors that affect the performance of the material that need to be considered, e.g., type and content of precursor, alkaline activator, curing temperature and time, liquid to solid ratio, among others. MIBA-based alkali-activated materials (AAM) can be produced with a very wide range of compressive strength (0.3–160 MPa). The main factor affecting the performance of this precursor is the existence of metallic aluminum (Al), which leads to damaging expansive reactions and an increase in porosity due to hydrogen gas generation stemming from the reaction with the alkaline activator. Several approaches have been proposed to eliminate this issue. The most effective solution was found to be the removal of Al by means of eddy current electromagnetic separation.

Influence of Activators on Mechanical Properties of Modified Fly Ash Based Geopolymer Mortars

The aim of this work was to study the influence of the type of activator on the formulation of modified fly ash based geopolymer mortars. Geopolymer and alkali-activated materials (AAM) were made from fly ashes derived from coal and biomass combustion in thermal power plants. Basic activators (NaOH, CaO, and Na₂SiO₃) were mixed with fly ashes in order to develop binding properties other than those resulting from the use of Portland cement. The results showed that the mortars with 5 mol/dm³ of NaOH and 100 g of Na₂SiO₃ (N5-S22) gave a greater compressive strength than other mixes. The compressive strengths of analyzed fly ash mortars with activators N5-S22 and N5-C10 (5 mol/dm³ NaOH and 10% CaO) varied from 14.3 MPa to 5.9 MPa. The better properties of alkali-activated mortars with regular fly ash were influenced by a larger amount of amorphous silica and alumina phases. Scanning electron microscopy and calorimetry analysis provided a better understanding of the observed mechanisms.

Importance of Cation Species during Sulfate Resistance Tests for Alkali-Activated FA/GGBFS Blended Mortars

In this study, the changes in mass, compressive strength, and length of blended mortars were analyzed to investigate their sulfate resistance according to the ground granulated blast furnace slag (GGBFS) blending ratio and type of sulfate solution applied. All alkali-activated mortars showed an excellent sulfate resistance when immersed in a sodium sulfate (Na₂SO₄) solution. However, when immersed in a magnesium sulfate (MgSO₄) solution, different sulfate resistance results were obtained depending on the presence of GGBFS. The alkali-activated GGBFS blended mortars showed a tendency to increase in mass and length and decrease in compressive strength when immersed in a magnesium sulfate solution, whereas the alkali-activated FA mortars did not show any significant difference depending on the types of sulfate solution applied. The deterioration of alkali-activated GGBFS blended mortars in the immersion of a magnesium sulfate solution was confirmed through the decomposition of C-S-H, which is the reaction product from magnesium ions, and the formation of gypsum (CaSO₄·2H₂O) and brucite (Mg(OH)₂).

Ambient Cured Fly Ash Geopolymer Coatings for Concrete

The reinforced concrete structures that support transport, energy and urban networks in developed countries are over half a century old, and are facing widespread deterioration. Geopolymers are an affordable class of materials that have promising applications in concrete structure coating, rehabilitation and sensing, due to their high chloride, sulphate, fire and freeze-thaw resistances and electrolytic conductivity. Work to date has, however, mainly focused on geopolymers that require curing at elevated temperatures, and this limits their ease of use in the field, particularly in cooler climates. Here, we outline a design process for fabricating ambient-cured fly ash geopolymer coatings for concrete substrates. Our technique is distinct from previous work as it requires no additional manufacturing steps or additives, both of which can bear significant costs. Our coatings were tested at varying humidities, and the impacts of mixing and application methods on coating integrity were compared using a combination of calorimetry, x-ray diffraction and image-processing techniques. This work could allow geopolymer coatings to become a more ubiquitous technique for updating ageing concrete infrastructure so that it can meet modern expectations of safety, and shifting requirements due to climate change.

Preliminary Research on the Physical and Mechanical Properties of Alternative Lightweight Aggregates Produced by Alkali-Activation of Waste Powders

There is growing interest in construction field issues related to environmental protection, energy saving and raw materials. Therefore, the interest in recycling waste materials to produce new construction ones is constantly increasing. This study proposes a new methodology to produce lightweight aggregates (LWAs) by alkali-activation of two different waste powders: a digested spent bentonite clay and a basalt powder. Metakaolin, as secondary precursor, was added to the mixtures according to mix-design proportions, to improve the mechanical properties of the final materials, while a specific activators mix of Sodium Silicate and Sodium Hydroxide enabled the alkali-activation. The expansion process, on the other hand, was obtained using Peroxide within the liquid mix. The experimental LWAs were analyzed and tested in compliance with the EN 13055-1 standard. A more in-depth analysis on LWAs' air voids content and porosity was also carried out by the means of Mercury Intrusion Porosimetry and Nuclear Magnetic Resonance. The results were compared with those obtained from commercial Lightweight Expanded Clay Aggregate, which represents one of the most common LWAs in the construction field. According to the presented preliminary results, the use of alkali-activated waste powders seems to be a suitable solution for the production of eco-friendly LWAs by allowing the recycling of waste materials and energy saving for their production.

Synthesis of Nanoscale CaO-Al₂O₃-SiO₂-H₂O and Na₂O-Al₂O₃-SiO₂-H₂O Using the Hydrothermal Method and Their Characterization

C-A-S-H (CaO-Al₂O₃-SiO₂-H₂O) and N-A-S-H (Na₂O-Al₂O₃-SiO₂-H₂O) have a wide range of chemical compositions and structures and are difficult to separate from alkali-activated materials. Therefore, it is difficult to analyze their microscopic properties directly. This paper reports research on the synthesis of C-A-S-H and N-A-S-H particles with an average particle size smaller than 300 nm by applying the hydrothermal method. The composition and microstructure of the products with different CaO(Na₂O)/SiO₂ ratios and curing conditions were characterized using XRD, the RIR method, FTIR, SEM, TEM, and laser particle size analysis. The results showed that the C-A-S-H system products with a low CaO/SiO₂ ratio were mainly amorphous C-A-S-H gels. With an increase in the CaO/SiO₂ ratio, an excess of Ca(OH)₂ was observed at room temperature, while in a high-temperature reaction system, katoite, C₄AcH₁₁, and other crystallized products were observed. The katoite content was related to the curing temperature and the content of Ca(OH)₂ and it tended to form at a high-temperature and high-calcium environment, and an increase in the temperature renders the C-A-S-H gels more compact. The main products of the N-A-S-H system at room temperature were amorphous N-A-S-H gels and a small amount of sodalite. An increase in the curing temperature promoted the formation of the crystalline products faujasite and zeolite-P. The crystallization products consisted of only zeolite-P in the high-temperature N-A-S-H system and its content were stable above 70%. An increase in the Na₂O/SiO₂ ratio resulted in more non-bridging oxygen and the TO₄ was more isolated in the N-A-S-H structure. The composition and microstructure of the C-A-S-H and N-A-S-H system products synthesized by the hydrothermal method were closely related to the ratio of the raw materials and the curing conditions. The results of this study increase our understanding of the hydration products of alkali-activated materials.

The Characterization of Fixation of Ba, Pb, and Cu in Alkali-Activated Fly Ash/Blast Furnace Slag Matrix

The fixation of heavy metals (Ba, Cu, Pb) in an alkali-activated matrix was investigated. The matrix consisted of fly ash and blast furnace slag (BFS). The mixture of NaOH and Na-silicate was used as alkaline activator. Three analytical techniques were used to describe the fixation of heavy metals—X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS), and X-ray powder diffraction (XRD). All heavy metals formed insoluble salts after alkaline activation. Ba was fixed as BaSO₄, and only this product was crystalline. EDS mapping showed that Ba was cumulated in some regions and formed clusters. Pb was present in the form of Pb(OH)₂ and was dispersed throughout the matrix on the edges of BFS grains. Cu was fixed as Cu(OH)₂ and also was cumulated in some regions and formed clusters. Cu was present in two different chemical states; apart from Cu(OH)₂, a Cu–O bond was also identified.