Search Results (538)

The civil construction and infrastructure sectors are known for their high environmental impact. Most of this impact is related to the carbon dioxide (CO₂) emissions from Portland cement. As a sustainable alternative, alkali-activated binders (AABs) are explored for their potential to replace traditional binders. This research focused on AAB formulations using steel industry byproducts, such as Baosteel’s slag short flow (BSSF), coke oven ash (CA), blast furnace sludge (BFS), and centrifuge sludge (CS), as well as fly ash (FA) from a thermoelectric plant. Byproducts were characterized through laser granulometry, Fourier transform infrared spectroscopy (FTIR), X-ray fluorescence (XRF), X-ray diffraction (XRD), and scanning electron microscopy (SEM), followed by the formulation of AABs with different precursor ratios. After 28 days, the compressive strength was obtained for each formulation. Based on the compressive strength tests, two binary mixtures were selected for microstructural and chemical analyses through XRF, FTIR, and SEM. CA demonstrated the greatest potential for use in binary AABs based on BSSF, as it presented a higher source of aluminosilicates and smaller particle sizes. The formulations containing BSSF and CA achieved compressive strengths of up to 9.8 MPa, while the formulations with BSSF and FA reached 23.5 MPa. SEM images revealed a denser, more cohesive matrix in the FA-based AAB, whereas CA-based AABs showed incomplete precursor dissolution and higher porosity, which contributed to the lower mechanical strength of CA-based AABs. These findings highlight the critical role of precursor selection in developing sustainable AABs from industrial byproducts and demonstrate how different formulations can be tailored for specific applications. Full article

The urgent demand for environmentally responsible construction practices has intensified interest in geopolymer concrete mixtures, which offer low-carbon alternatives to conventional Portland cement by enabling the valorization of industrial by-products. Since the large volume of waste generated by mining activities represents a significant environmental liability, this research aimed to utilize the alkali activation technique in mixtures of soil and bauxite residue, commonly known as red mud (RM), for application in green construction. All raw materials were characterized based on their physical and chemical properties. To evaluate the influence of waste content on the mechanical behavior of the geopolymers, specimens were prepared with soil contents ranging from 70% to 100% and RM dosages ranging from 0% to 30%. These mixtures underwent compaction tests using the standard Proctor energy method to determine maximum dry density and optimum moisture content. Using the optimal mixture compositions, specimens were prepared for unconfined compressive strength (UCS) tests, with NaOH at a concentration of 6 mol/L added as an activator. The experimental tests provided UCS results ranging from 2.23 MPa to 3.05 MPa. X-ray diffraction (XRD) analyses were performed on raw materials and mixtures containing 70% soil and 30% waste to assess changes in mineralogical compositions due to waste incorporation. The results confirmed the potential of alkali activation for stabilizing mixtures of soil and RM for sustainable construction. Full article

In recent decades, replacing clinker in cement with mineral additives has become increasingly common, and the range of such additives continues to expand. An example is the growing number of cement types defined in European standards. Some of these standards allow the use of fine recycled concrete waste as an active additive in amounts up to 35%.. Finely ground waste glass, whose quantity steadily increases worldwide, can also be classified as an active additive. Due to its relatively high silica content, finely ground waste glass is a potential supplementary cementitious material. However, the high alkali content in glass limits its use in cementitious products to 5–10% of the binder mass. Considering that silicate binders (water glass) with high alkali activity are also used in construction and influence the hydration process of cement, it can be assumed that waste glass likewise has a significant impact on the properties of cement composites, particularly on hardening parameters and the development of mechanical strength. However, scientific literature lacks data on the synergistic effect of alkaline components of finely ground waste glass and water glass on the cement hydration process, its hardening, and the strength of cement products. Therefore, this study aimed to analyze the mechanism of the influence of a glass-based composite, consisting of waste glass additives and water glass, on the physicochemical and mechanical properties of cement composites. Full article

Magnesium slag (MS) is a solid by-product during magnesium production using the Pidgeon process. Around 5–6 million tons of magnesium slag was produced in China in 2023, which accounted for 83% of the total disposal of magnesium slag worldwide. To explore the innovative and high-end application of MS in building materials, this study investigated the preparation of calcium carbonate cementitious composites produced by high-volume (80%) MS and 20% of traditional ordinary Portland cement (OPC), low-carbon cement–calcium sulfoaluminate cement (CSA), or green cement–alkali-activated materials after CO₂ curing. The effects of OPC, CSA, and AAM on the performance evolution of MS blends before and after carbonation curing were analyzed. The results indicated that AAM contributed to a superior initial strength (7.38 MPa) of MS composites after standard curing compared to OPC (1.18 MPa) and CSA (2.72 MPa). However, the lack of large pores (around 1000 nm) in the AAM-MS binder caused the slowest CO₂ penetration during the carbonation curing period compared to the OPC- and CSA-blended samples. Less than 3 days were required for the full carbonation of the CSA- and OPC-blended MS mortar, while 7 days were required for the AAM blends. After carbonation, the OPC-blended MS exhibited the highest strength performance of 51.58 MPa, while 21.38 MPa and 9.3 MPa were reached by the AAM- and CSA-blended MS mortars, respectively. OPC-blended MS composites exhibited the highest CO₂ uptake of 13.82% compared to the CSA (10.85%) and AAM (9.41%) samples. The leaching of Hg was slightly higher than the limit (<50 µg/L) in all MS mortars, which should be noticed in practical application. Full article

This research presents a novel methodology to classify copper tailings according to their potential as alkali-activated materials (AAMs) for construction applications. The methodology includes geochemical and mineralogical characterization via QEMSCAN and X-ray fluorescence, with mechanical performance evaluation through compressive strength test (UCS). A three-phase diagram based on Al₂O₃, Fe₂O₃, and CaO-MgO-K₂O is proposed for a fast screening of copper tailing potential to be used as a construction material. In this paper, three copper tailings were chosen to test the methodology, and a set of five samples for each tailing have been geopolymerized for testing. Copper tailing samples were mixed with 0, 2.5, 5, 7.5 and 10% by mass of Ordinary Portland Cement (OPC) to evaluate the effect on performance when a chemical co-activator is used to improve material reactivity. Compressive strength testing was applied on 2 cm³ cubes after 28 days of curing at 60 °C, yielding values from 6 to 26.1 MPa. The best performing sample featured a Si/Al ≅ 3 ratio and a mineralogy with significant presence of reactive species such as plagioclase and K-feldspar (≅42%). In contrast, high levels of Fe₂O₃ (≥12%), clay (≥7%), and pyrite (≥4%) were associated with reduced mechanical performance. Full article

This study evaluated the feasibility of reusing abandoned copper mine tailings (Cu tailings) as a precursor in the production of fly-ash-based alkali-activated materials (FA-AAMs). Two formulations were developed by combining FA and Cu tailings with a mixture of sodium silicate and sodium hydroxide as alkaline activators at room temperature (20 °C). Formulation G1 consisted of 70% Cu tailings and 30% fly ash (FA), whereas G2 included the same composition with an additional 15% ordinary Portland cement (OPC). The materials were characterized using X-ray fluorescence (XRF), -X-ray diffraction (XRD), field emission scanning electron microscopy with energy-dispersive spectroscopy (FESEM-EDS), and particle size analysis. While FA exhibited a high amorphous content (64.4%), Cu tailings were largely crystalline and acted as inert fillers. After 120 days of curing, average compressive strength reached 24 MPa for G1 and 41 MPa for G2, with the latter showing improved performance due to synergistic effects of geopolymerization and OPC hydration. Porosity measurements revealed a denser microstructure in G2 (35%) compared to G1 (52%). Leaching tests confirmed the immobilization of hazardous elements, with arsenic concentrations decreasing over time and remaining below regulatory limits. Despite extended setting times (24 h for G1 and 18 h for G2) and the appearance of surface efflorescence, both systems demonstrated good chemical stability and long-term performance. The results support the use of Cu tailings in FA-AAMs as a sustainable strategy for waste valorization, enabling their application in non-structural and moderate-load-bearing construction components or waste encapsulation units. This approach contributes to circular economy goals while reducing the environmental footprint associated with traditional cementitious systems. Full article

Alkali-activated fly ash and slag binders are regarded as environmentally friendly building materials. However, the creep properties of the alkali-activated materials differ from ordinary Portland cement-based materials. Currently, predicting the creep properties of alkali-activated materials is difficult. This study tested the creep properties of alkali-activated materials with various strengths and loading ages, exploring the similarities and differences in the creep properties between alkali-activated and cement-based materials. The result shows that the creep development of alkali-activated materials still conforms to the law of the hyperbolic power function commonly used to describe that of cement-based materials. Nevertheless, the proportion of the basic creep increases to about 70% of the drying creep in alkali-activated materials at 90 days. By modifying the parameters related to the relative humidity in the model of CEB-FIP MC2010, the creep behavior of alkali-activated fly ash and slag concrete could be well predicted. Full article

Cementitious materials are susceptible to water ingress due to their hydrophilicity and porous microstructure, which can cause premature destruction and compromise long-term durability. Integral hydrophobic modification using alkyl silanes is an effective strategy for enhancing water resistance, while the influence of different silanes on early-age properties (within the first 7 d) of various binder systems remains unclear. This study investigates the rheology, flowability, setting behavior, reaction kinetics, compressive strength, and hydrophobicity of ordinary Portland cement (OPC) and alkali-activated fly ash–slag (AAFS) pastes incorporating alkyl silanes of varying alkyl chain lengths, i.e., methyl-(C1TMS), butyl-(C4TMS), octyl-(C8TMS), and dodecyl-trimethoxysilane (C12TMS). In OPC, C1TMS reduced yield stress and plastic viscosity by 33.6% and 21.0%, respectively, and improved flowability by 27.6%, whereas C4TMS, C8TMS, and C12TMS showed the opposite effects. In contrast, the effect of alkyl silanes on rheology and flowability of AAFS was less pronounced. Silanes delayed setting of OPC and AAFS by 5.6–164.4%, with shorter alkyl chains causing greater retardation. C1TMS and C4TMS inhibited early-age heat release and decreased the 1-day compressive strength by 14.8–35.7% in OPC and 82.0–84.5% in AAFS, whereas longer-chain silanes had comparatively minor effects. The hydrophobic performance in both binder systems was strongly correlated with alkyl chain length. C8TMS exhibited the best hydrophobicity in OPC, achieving a water contact angle of 145° and a 75.7% reduction in water sorptivity, while C4TMS demonstrated the highest hydrophobicity in AAFS. This study provides fundamental guidance for the rational selection of alkyl silanes in OPC and AAFS systems, offering insights into the design of multifunctional water-resistant cementitious composites for marine structures, building facades, and other applications with waterproofing requirements. Full article

The development of innovative and environmentally sustainable construction materials is a strategic priority in the context of the ecological transition and circular economy. Geopolymers and alkali-activated materials, derived from industrial and construction waste rich in aluminosilicates, are gaining increasing attention as low-carbon alternatives to ordinary Portland cement (OPC), which remains one of the main contributors to anthropogenic CO₂ emissions and landfill-bound construction waste. This review provides a comprehensive analysis of geopolymer-based solutions for building and architectural applications, with a particular focus on modular multilayer panels. Key aspects, such as chemical formulation, mechanical and thermal performance, durability, technological compatibility, and architectural flexibility, are critically examined. The discussion integrates considerations of disassemblability, reusability, and end-of-life scenarios, adopting a life cycle perspective to assess the circular potential of geopolymer building systems. Advanced fabrication strategies, including 3D printing and fibre reinforcement, are evaluated for their contribution to performance enhancement and material customisation. In parallel, the use of parametric modelling and digital tools such as building information modelling (BIM) coupled with life cycle assessment (LCA) enables holistic performance monitoring and optimisation throughout the design and construction process. The review also explores the emerging application of artificial intelligence (AI) and machine learning for predictive mix design and material property forecasting, identifying key trends and limitations in current research. Representative quantitative indicators demonstrate the performance and environmental potential of geopolymer systems: compressive strengths typically range from 30 to 80 MPa, with thermal conductivity values as low as 0.08–0.18 W/m·K for insulating panels. Life cycle assessments report 40–60% reductions in CO₂ emissions compared with OPC-based systems, underscoring their contribution to climate-neutral construction. Although significant progress has been made, challenges remain in terms of long-term durability, standardisation, data availability, and regulatory acceptance. Future perspectives are outlined, emphasising the need for interdisciplinary collaboration, digital integration, and performance-based codes to support the full deployment of geopolymer technologies in sustainable building and architecture. Full article

In the construction sector, cement and concrete are among the most widely utilized manufactured materials, yet their environmental impact remains a significant concern. The concrete industry is a major contributor to carbon dioxide emissions, accounting for over 8% of global greenhouse gas emissions annually. Several reports have estimated that between 1930 and 2013, a total of 4.5 gigatons of carbon was sequestered through the carbonation of cement-based materials. This process offset approximately 43% of the carbon dioxide (CO₂) emissions resulting from cement production during the same period, excluding emissions related to fossil fuel consumption in the manufacturing process. It is well established that producing one ton of cement results in approximately 0.60–0.98 tons of CO₂ emissions, coupled with substantial energy consumption. To mitigate these environmental effects, developing low-carbon or cement-free binders has become crucial. Alkali-activated binders (AABs), derived from industrial by-products or agricultural waste materials and activated with a low-molarity or one-part activator, are increasingly recommended as sustainable alternatives to reduce greenhouse gas emissions in the cement industry and minimize the consumption of natural resources. The production of alkali-activated concrete (AAC) involves several critical factors that significantly influence its mix design, fresh properties, and compressive strength (CS) performance. This study aims to provide a comprehensive review of the key factors affecting AAC’s mix design, workability, and CS characteristics. Firstly, the study discusses various methods employed for AAC mix design and the factors influencing these designs. Secondly, it examines the impact of binder type, source, chemical, mineralogical, and physical properties, as well as alkaline activator solutions, water content, and fillers on AAC’s workability, setting times, and strength development. Additionally, the study explores the correlation matrix and predictive performance models for fresh and strength properties. Lastly, the relationship between workability and CS is extensively analyzed. The review concludes by highlighting the existing challenges and prospects of AACs as sustainable construction materials to replace traditional cement and reduce carbon emissions. Full article

Geopolymers are an environmentally sustainable class of low-calcium alkali-activated materials (AAMs), distinct from high-calcium C–A–S–H gel systems. Synthesized from aluminosilicate-rich precursors such as fly ash, metakaolin, slag, waste glass, and coal gasification fly ash (CGFA), geopolymers offer a significantly lower carbon footprint, valorize industrial by-products, and demonstrate superior durability in aggressive environments compared to Ordinary Portland Cement (OPC). Recent advances in thermodynamic modeling and phase chemistry, particularly in CaO–SiO₂–Al₂O₃ systems, are improving precursor selection and mix design optimization, while Artificial Neural Network (ANN) and hybrid ML-thermodynamic approaches show promise for predictive performance assessment. This review critically evaluates geopolymer chemistry and composition, emphasizing precursor reactivity, Si/Al and other molar ratios, activator chemistry, curing regimes, and reaction mechanisms in relation to microstructure and performance. Comparative insights into alkali aluminosilicate (AAS) and aluminosilicate phosphate (ASP) systems, supported by SEM and XRD evidence, are discussed alongside durability challenges, including alkali–silica reaction (ASR) and shrinkage. Emerging applications ranging from advanced pavements and offshore scour protection to slow-release fertilizers and biomedical implants are reviewed within the framework of the United Nations Sustainable Development Goals (SDGs). Identified knowledge gaps include standardization of mix design, LCA-based evaluation of novel precursors, and variability management. Aligning geopolymer technology with circular economy principles, this review consolidates recent progress to guide sustainable construction, waste valorization, and infrastructure resilience. Full article

When coal gasification slag is used as a substitute for cement, the prepared cementitious materials may exhibit inadequate properties due to the slag’s limited hydration reactivity, which limits its effectiveness in applications of backfill materials. In this study, alkali activation was used to improve the hydration activity of coal gasification slag. The effect of alkali equivalent on the setting time, rheological properties, and uniaxial compressive strength of the alkali-activated coal gasification slag-based backfill material (ACBM) sample was systematically investigated, and the optimal alkali equivalent was identified. The mineral composition, pore structure, and micromorphology of ACBM samples were characterized using the X-ray diffractometer (XRD), nitrogen adsorption–desorption analyzer (BET), and scanning electron microscope–energy dispersion spectrum (SEM-EDS). The results show that when the alkali equivalent is 4%, the comprehensive performance of ACBM samples is optimal. At this time, the initial setting time and final setting time of ACBM samples are 125 min and 172 min, and the rheological properties are in accordance with the Herschel–Bulkley model. The yield stress, plastic viscosity, and hysteresis loop area are 9.22 Pa, 0.74 Pa·s, and 1014 Pa/s, respectively, and the compressive strength of the ACBM sample at the curing age of 28 days is 2.18 MPa. When the alkali equivalent is further increased to 6%, the initial hydration reaction becomes more intense due to the excessive alkali level, leading to a rapid decline in flowability; the sample cracked at 28 days and its strength decreased considerably. This study provides theoretical guidance for the application of coal gasification slag in the field of backfill mining. Full article

Portland cement production is a major source of global CO₂ emissions due to its high energy consumption and calcination processes. This study proposes a sustainable alternative through the partial replacement of cement with alkali-activated pumice, a naturally occurring aluminosilicate material with high regional availability. Mixes with 0%, 10%, 20%, and 30% cement replacement were designed for pedestrian slabs exposed to humid tropical conditions. Compressive strength was evaluated using non-destructive testing over a period of 364 days, and carbonation was analyzed at different ages. The results show that mixes with up to 30% pumice maintain adequate strength levels for light-duty applications, although with a more gradual strength development. A significant reduction in carbonation depth was also observed, especially in the mix with the highest replacement level, suggesting greater durability in aggressive environments. These findings support the use of pumice as a viable and sustainable supplementary cementitious material in tropical regions, promoting low-impact construction practices. Full article

This paper presents a comprehensive review of dealuminated metakaolin (DK), a hazardous industrial by-product generated by the aluminium sulphate (alum) industry and evaluates its potential as a component in cementitious systems for the partial or full replacement of Portland cement (PC). Positioned within the context of waste valorisation in concrete, the review aims to establish a critical understanding of DK formation, properties, and reactivity, particularly its pozzolanic potential, to assess its suitability for use as a supplementary cementitious material (SCM), or as a precursor in alkali-activated cement (AAC) systems for concrete. A systematic methodology is used to extract and synthesise relevant data from existing literature concerning DK and its potential applications in cement and concrete. The collected information is organised into thematic sections exploring key aspects of DK, beginning with its formation from kaolinite ores, followed by studies on its pozzolanic reactivity. Applications of DK are then reviewed, focusing on its integration into SCMs and alkali-activated cement (AAC) systems. The review consolidates existing knowledge related to DK, identifying scientific gaps and practical challenges that limit its broader adoption for cement and concrete applications, and outlines future research directions to provide a solid foundation for future studies. Overall, this review highlights the potential of DK as a low-carbon, circular-economy material and promotes its integration into efforts to enhance the sustainability of construction practices. The findings aim to support researchers’ and industry stakeholders’ strategies to reduce cement clinker content and mitigate the environmental footprint of concrete in a circular-economy context. Full article

This study investigates the feasibility of using volcanic lapillus as a supplementary cementitious material (SCM) in mortar production to improve the sustainability of the cement industry. Cement production is one of the main sources of CO₂ emissions, mainly due to clinker production. Replacing clinker with SCMs, such as volcanic lapillus, can reduce the environmental impact while maintaining adequate mechanical properties. Experiments were conducted to replace up to 20 wt% of limestone Portland cement with volcanic lapillus. Workability, compressive strength, microstructure, resistance to alkali-silica reaction (ASR), sulfate, and chloride penetration were analyzed. The results showed that up to 10% replacement had a minimal effect on mechanical properties, while higher percentages resulted in reduced strength but still improved some durability features. The control sample cured 28 days showed a compressive strength of 43.05 MPa compared with 36.89 MPa for the sample containing 10% lapillus. After 90 days the respective values for the above samples were 44.76 MPa and 44.57 MPa. Scanning electron microscopy (SEM) revealed good gel–aggregate adhesion, and thermogravimetric analysis (TGA) confirmed reduced calcium hydroxide content, indicating pozzolanic activity. Overall, volcanic lapillus shows promise as a sustainable SCM, offering CO₂ reduction and durability benefits, although higher replacement rates require further optimization. Full article