Coal mining wastes are associated with serious environmental problems; they have potential as building materials, including alkali-activated cement. In this study, the effect of different coal mining wastes on the mechanical properties and microstructural development of alkali-activated materials (AAMs) was evaluated through XRD, SEM and FTIR spectroscopy. Different alkali-activated compounds were produced; the alkaline solution was composed of NaOH+Na2SiO3. The results obtained using the calcined coal sludge showed excellent mechanical performance, with compressive strength higher than 60 MPa. However, addition of metakaolin and ordinary Portland cement was necessary to increase the mechanical performance of calcined coal gangue materials. The formation of N-A-S-H gel and the incorporation of iron ions into the cementitious matrix were evidenced. Ultrasonic pulse velocity indicated the early polymerization during the reaction processes. The study verified that the different characteristics of the wastes influence the performance of alkali-activated materials.

The study of alternative binders to Portland cement, such as geopolymer cements, offers the chance to develop materials with different properties. With this purpose, this study evaluated experimentally the mechanical behavior of a geopolymer concrete beam and compared to a Finite Element (FE) nonlinear numerical model. Two concrete beams were fabricated, one of Portland cement and another of metakaolin-based geopolymer cement. The beams were instrumented with linear variable differential transformers and strain gauges to measure the deformation of the concrete and steel. Values for the compressive strength of the geopolymer cement concrete was 8% higher than the Portland cement concrete (55 MPa and 51 MPa, respectively) and the tensile rupture strength was also 8% higher (131 kN) for the geopolymer concrete beam in relation to Portland cement concrete beam (121 kN). Distinct failure mechanisms were verified between the two samples, with an extended plastic deformation of the geopolymer concrete, revealing post-fracture toughness. The geopolymer concrete showed higher tensile strength and better adhesion in cement-steel interface.

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Among the advances in the use of geopolymer cements is their use as repair materials in concrete structures. The objective of this work was to use a geopolymer cement to repair cracks in concrete specimens, observing its mechanical performance and fracture modes. Cubic test specimens were produced and two types of cracks were evaluated as variables. Cracks were induced by steel sheets during concreting. The geopolymer cement paste and an epoxy adhesive, as reference, were used for the repairs. The results showed a 13% decrease in compressive strength for unrepaired concrete, and 3.7% in concrete repaired with geopolymer. The binder presented mechanical performance similar to that of the epoxy resin regarding crack recovery. In conclusion, repairs made with geopolymer cement are a viable and efficient means of crack recovery.