Effect of type, form, and dosage of activators on strength of alkali-activated natural pozzolans

It is possible to synthesize environmentally friendly cementitious construction materials from alkali-activated natural pozzolans. The effect of the alkaline medium on the strength of alkali-activated natural pozzolans has been investigated and characterised. This paper highlights the effect of the type and form of the alkaline activator, the dosage of alkali and the SiO2/Na2O ratio (silica modulus, Ms) when using water–glass solutions and different curing conditions on the geopolymerisation of natural pozzolans. Activation of natural and calcined pozzolan for production of geopolymeric binder was verified by using Taftan andesite and Shahindej dacite from Iran as a solid precursor. The optimum range for each factor is suggested based on the different effects they have on compressive strength. The concentration of dissolving silicon, aluminium and calcium in alkaline solution, the formation of gel phase and the factors affecting this have been studied by using leaching tests, ICP–AES, and FTIR.

Effect of adding mineral additives to alkali-activated natural pozzolan paste

Natural pozzolans are raw materials from geological deposits with a range of chemical compositions that when combined with suitable alkali activators can be converted to geopolymer cement for concrete production. In this paper the concept of adding mineral additives to enhance the properties of geopolymer cement is introduced. Taftan andesite, a natural Iranian pozzolan, was used to study the effect of adding mineral additives such as kaolinite, lime and other calcined pozzolans on the compressive strength of geopolymer cement under both normal and autoclave curing. Scanning electron microscopy (SEM)/energy dispersive X-ray (EDX) was used to determine the composition of the gel phase in both alkali-activated Taftan pozzolan with and without mineral additions. The work has shown that deficiencies in SiO2, Al2O3 and CaO content in the raw natural pozzolan can be compensated for by adding mineral additives for enhanced properties.

Effect of heat treatment on reactivity-strength of alkali-activated natural pozzolans

Natural pozzolans can be activated and condensed with sodium silicate in an alkaline environment to synthesize high performance cementitious construction materials with low environmental impact. The nature of the starting materials including mineral composition, chemical composition and crystal structure groups affects the formation of the geopolymer gel phase. In this paper, the pozzolanic activities of five natural pozzolans are studied. From XRD and XRF results, most of the raw materials contain zeolite clay minerals and have a high loss on ignition. Therefore, before use, samples were calcined at 700, 800 and 900 °C, respectively. The improvement in pozzolanic properties was studied following heat treatment including calcinations and/or elevated curing temperature by using alkali solubility and compressive strength tests. The results show that pozzolan containing sodium zeolite clinoptilolite can be used to prepare a moderate to high strength binder by heat treatment and calcinations can impart disorder hornblende as a constituent of pozzolan with no amorphous phase to prepare a moderate strength binder.

Mechanism of effluent attack on Portland cement and alkali activated mortars

The alkali activation of waste products has become a widespread topic of research, mainly due to environmental benefits. Portland cement and alkali-activated mortar samples were prepared to compare their resistance to silage effluent which contains lactic acid. The mechanism of attack on each sample has also been investigated.

Strength and drying shrinkage of reactive MgO modified alkali-activated slag paste

Conventional alkali-activated slag (AAS) cements suffer from significant drying shrinkage which hinders their widespread application. This paper investigates the potential of using commercial reactive MgO to reduce the drying shrinkage of AAS. Two different reactive MgOs were added at a content of 2.5-7.5 wt% of the slag, which was activated by sodium hydroxide and water-glass. The strength and the drying shrinkage of those reactive MgO modified AAS (MAAS) pastes were measured up to 90 days. It is found that MgO with high reactivity accelerated the early hydration of AAS, while MgO with medium reactivity had little effect. The drying shrinkage was significantly reduced by highly reactive MgO but it also generated severe cracking under the dry condition. On the other hand, medium-reactive MgO only showed observable shrinkage-reducing effect after one month, but the cement soundness was improved. The hydration products, analysed by X-ray diffraction, thermogravimetric analysis and scanning electron microscopy techniques, showed that Mg was mainly incorporated in the hydrotalcite-like phases. It is concluded that the curing conditions and the time of hydrotalcite-like phases formation and their quantity are crucial to the developed strength and shrinkage reduction properties of MAAS, which are highly dependent on the reactivity and content of reactive MgO. Crown Copyright © 2013 Published by Elsevier Ltd. All rights reserved.

Alkali Activated Fuel Ash and Slag Mixes:Optimization Study from Mortars to Concrete Building Blocks

Alkali activated binders, based on ash and slag, also known as geopolymers, can play a key role in reducing the carbon footprint of the construction sector by replacing ordinary Portland cement in some concretes. Since 1970s, research effort has been ongoing in many research institutions. In this study, pulverized fuel ash (PFA) from a UK power plant, ground granulated blast furnace slag (GGBS) and combinations of the two have been investigated as geopolymer binders for concrete applications. Activators used were sodium hydroxide and sodium silicate solutions. Mortars with sand/binder ratio of 2.75 with several PFA and GGBS combinations have been mixed and tested. The optimization of alkali dosage (defined as the Na2O/binder mass ratio) and modulus (defined as the Na2O/SiO2 mass ratio) resulted in strengths in excess of 70 MPa for tested mortars. Setting time and workability have been considered for the identification of the best combination of PFA/GGBS and alkali activator dosage for different precast concrete products. Geopolymer concrete building blocks have been replicated in laboratory and a real scale factory trial has been successfully carried out. Ongoing microstructural characterization is aiming to identify reaction products arising from PFA/GGBS combinations.

Chloride induced corrosion of steel in alkali activated slag concretes

Alkali activated slag (AAS) is an alternative cementitious material. Sodium silicate solution is usually used to activate ground granulated blast furnace slag to produce AAS. As a consequence, the pore solution chemistry of AAS differs from that of Portland cement (PC). Although AAS offers many advantages over PC, such as higher strength, superior resistance to acid and sulphate environments and lower embodied carbon due to 100% PC replacement, there is a need to assess its performance against chloride induced corrosion duo to its different pore solution chemistry. For PC systems, resistivity measurement, as a type of nondestructive test, is usually used to evaluate its chloride diffusivity and the corrosion rate of the embedded steel. However, due to the different pore solution chemistry present in the different AAS systems, the application of this test in AAS concretes would be questionable as the resistivity of concrete is highly dependent on its conductivity of the pore solution. Therefore, a study was carried out using twelve AAS concretes mixes, the results of which are reported in this paper. The AAS mixes were designed with alkali concentration of 4%, 6% and 8% (Na₂O% of the mass of slag) and modulus (Ms) of sodium silicate solution of 0.75, 1.00, 1.50 and 2.00. A PC concrete with the same binder content as the AAS concretes was also studied as a reference. The chloride diffusion coefficient was determined using a non-steady state chloride diffusion test (NT BUILD 443). The resistivity of the concretes before the diffusion test was also measured. Macrocell corrosion current (corrosion rate) for steel rods embedded in the concretes was measured whilst subjecting the concretes to a cyclic chloride ponding regime (1 day ponded with salt solution and 6 days drying). The results showed that the AAS concretes had lower chloride diffusivity with associated higher resistivity than the PC concrete. The measured corrosion rate was also lower for the AAS concretes. However, unlike the PC, in which a higher resistivity yields a lower diffusivity and corrosion rate, there was no relationship apparent between the resistivity and either the diffusivity or the corrosion rate of steel for the AAS concretes. This is assigned to the variation of the pore solution composition of the AAS concretes. This also means that resistivity measurements cannot be depended on for assessing the chloride induced corrosion resistance of AAS concretes.

Chloride ingress through alkali activated slag concretes

Alkali activated slag (AAS) is a credible alternative to Portland cement (PC) based binder systems. The superior strength gain and low embodied carbon make it a potential binder for next generation concretes. However there is little known about the long term durability of AAS systems, especially the chloride transport and subsequent corrosion of reinforcing steel.
In this study, chloride transport through 12 AAS concretes with different alkali concentrations (Na2O% of mass of slag) and different modulus (Ms) of sodium silicate solution activator was investigated. A non-steady state chloride diffusion test was used for this study due to its similarity to the real exposure environment in terms of chloride transport through concrete. The results showed that the chloride concentration at the surface (Cs) of AAS concretes was higher than that for PC concrete.
However, lower non-steady state chloride diffusion coefficient (Dnssd) was obtained for the AAS concretes. The Dnssd of the AAS concretes decreased with the increase of Na2O% and Ms of 1.50 gave the lowest Dnssd. The results are encouraging and it can be concluded that AAS concrete offers a superior performance in terms of chloride transport.

The Role of Water Content and Paste Proportion on Physico-mechanical Properties of Alkali Activated Fly Ash–Ggbs Concrete

The growth of the construction industry worldwide poses a serious concern on the sustainability of the building material production chain, mainly due to the carbon emissions related to the production of Portland cement. On the other hand, valuable materials from waste streams, particularly from the metallurgical industry, are not used at their full potential. Alkali activated concrete (AAC) has emerged in the last years as a promising alternative to traditional Portland cement based concrete for some applications. However, despite showing remarkable strength and durability potential, its utilisation is not widespread, mainly due to the lack of broadly accepted standards for the selection of suitable mix recipes fulfilling design requirements, in particular workability, setting time and strength. In this paper, a contribution towards the design development of AAC synthetized from pulverised fuel ash (60%) and ground granulated blast furnace slag (40%) activated with a solution of sodium hydroxide and sodium silicate is proposed. Results from a first batch of mixes indicated that water content influences the setting time and that paste content is a key parameter for controlling strength development and workability. The investigation indicated that, for the given raw materials and activator compositions, a minimum water to solid (w/s) ratio of 0.37 was needed for an initial setting time of about 1 hour. Further work with paste content in the range of 30% to 33% determined the relationship between workability and strength development and w/s ratio and paste content. Strengths in the range of 50 - 60 MPa were achieved.

Alkali activated fuel ash and slag mixes:optimization study from paste to concrete building blocks

Alkali activated binders, based on ash and slag, also known as geopolymers, can play a key role in reducing the carbon footprint of the construction sector by replacing ordinary Portland cement in some concretes. Since 1970s, research effort has been ongoing in many research institutions. In this study, pulverized fuel ash (pfa) from a UK power plant, ground granulated blast furnace slag (ggbs) and combinations of the two have been investigated as geopolymer binders for concrete applications. Activators used were sodium hydroxide and sodium silicate solutions. Mortars with sand/binder ratio of 2.75 with several pfa and ggbs combinations have been mixed and tested. The optimization of alkali dosage (defined as the Na2O/binder mass ratio) and modulus (defined as the Na2O/SiO2 mass ratio) resulted in strengths in excess of 70 MPa for tested mortars. Setting time and workability have been considered for the identification of the best combination of pfa/ggbs and alkali activator dosage for different precast concrete products. Geopolymer concrete building blocks have been replicated in laboratory and a real scale factory trial has been successfully carried out. Ongoing microstructural characterization is aiming to identify reaction products arising from pfa/ggbs combinations.

Chloride transport and the resulting corrosion of steel bars in alkali activated slag concretes

As the relative performance of alkali activated slag (AAS) concretes in comparison to Portland cement (PC) counterparts for chloride transport and resulting corrosion of steel bars is not clear, an investigation was carried out and the results are reported in this paper. The effect of alkali concentration and modulus of sodium silicate solution used in AAS was studied. Chloride transport and corrosion properties were assessed with the help of electrical resistivity, non-steady state chloride diffusivity, onset of corrosion, rate of corrosion and pore solution chemistry. It was found that: (i) although chloride content at surface was higher for the AAS concretes, they had lower chloride diffusivity than PC concrete; (ii) pore structure, ionic exchange and interaction effect of hydrates strongly influenced the chloride transport in the AAS concretes; (iii) steel corrosion resistance of the AAS concretes was comparable to that of PC concrete under intermittent chloride ponding regime, with the exception of 6% Na2O and Ms of 1.5; (iv) the corrosion behaviour of the AAS concretes was significantly influenced by ionic exchange, carbonation and sulphide concentration; (v) the increase of alkali concentration of the activator generally increased the resistance of AAS concretes to chloride transport and reduced its resulting corrosion, and a value of 1.5 was found to be an optimum modulus for the activator for improving the chloride transport and the corrosion resistance.

Chloride induced corrosion of steel bars in alkali activated slag concretes

The studies on chloride induced corrosion of steel bars in alkali activated slag (AAS) concretes are scarcely reported in the past. In order to make this issue clearer and compare the corrosion performance of AAS with Portland cement (PC) counterpart, an investigation was carried out and the results are reported in this paper. Corrosion properties were assessed with the help of rate of corrosion, electrical resistivity and pore solution chemistry. It was found that: (i) steel corrosion resistance of the AAS concretes was comparable or in some cases even worse than that of Portland cement (PC) concrete under intermittent chloride ponding regime; (ii) the corrosion behaviour of the AAS concretes was significantly influenced by ionic exchange, carbonation and sulphide concentration; (iii) the increase of alkali concentration of the activator generally reduced chloride resulting corrosion, and a value of 1.5 was found to be an optimum modulus for the activator for improving the corrosion resistance.

Alkali activated materials based on fluid catalytic cracking catalyst residue (FCC): Influence of SiO2/Na2O and H 2O/FCC ratio on mechanical strength and microstructure

Reuse of industrial and agricultural wastes as supplementary cementitious materials (SCMs) in concrete and mortar productions contribute to sustainable development. In this context, fluid catalytic cracking catalyst residue (spent FCC), a byproduct from the petroleum industry and petrol refineries, have been studied as SCM in blended Portland cement in the last years. Nevertheless, another environmental friendly alternative has been conducted in order to produce alternative binders with low CO2 emissions. The use of aluminosilicate materials in the production of alkali-activated materials (AAMs) is an ongoing research topic which can present low CO2 emissions associated. Hence, this paper studies some variables that can influence the production of AAM based on spent FCC. Specifically, the influence of SiO 2/Na2O molar ratio and the H2O/spent FCC mass ratio on the mechanical strength and microstructure are assessed. Some instrumental techniques, such as SEM, XRD, pH and electrical conductivity measurements, and MIP are performed in order to assess the microstructure of formed alkali-activated binder. Alkali activated mortars with compressive strength up to 80 MPa can be formed after curing for 3 days at 65°C. The research demonstrates the potential of spent FCC to produce alkali-activated cements and the importance of SiO2/Na2O molar ratio and the H2O/spent FCC mass ratio in optimising properties and microstructure. © 2013 Elsevier Ltd. All rights reserved.

Self-sensing properties of alkali activated blast furnace slag (BFS) composites reinforced with carbon fibers

In recent years, several researchers have shown the good performance of alkali activated slag cement and concretes. Besides their good mechanical properties and durability, this type of cement is a good alternative to Portland cements if sustainability is considered. Moreover, multifunctional cement composites have been developed in the last decades for their functional applications (self-sensing, EMI shielding, self-heating, etc.). In this study, the strain and damage sensing possible application of carbon fiber reinforced alkali activated slag pastes has been evaluated. Cement pastes with 0, 0.29 and 0.58 vol % carbon fiber addition were prepared. Both carbon fiber dosages showed sensing properties. For strain sensing, function gage factors of up to 661 were calculated for compressive cycles. Furthermore, all composites with carbon fibers suffered a sudden increase in their resistivity when internal damages began, prior to any external signal of damage. Hence, this material may be suitable as strain or damage sensor.

Establishment of a preconditioning regime for air permeability and sorptivity of alkali-activated slag concrete

This study reports an experimental investigation designed to assess the influence of near-surface moisture contents on permeation properties of alkali-activated slag concrete (AASC). Five different drying periods (5, 10, 15, 20 and 25 days) and three AASC and normal concretes with compressive strength grades ranging from C30 to C60 were considered. Assessment of moisture distribution was
achieved using 100 mm diameter cores with drilled cavities. Results indicate that air permeability of AASC is very sensitive to the moisture content and its spatial distribution, especially at relative humidity above 65%. To control the influence of moisture on permeation testing, the recommendation of this paper is that AASC specimens should be dried in controlled conditions at 40 C for 10 days prior to testing. It was also concluded from this study that AASC tends to perform less well, in terms of air permeability and sorptivity, than normal concrete for a given strength grade. This conclusion reinforces the need to further examine AASC properties prior to its widespread practical use.