One-part alkali-activated materials prepared with solid-form alkali activator are gaining attention in the construction industry, as they are an easier and safer approach for cast-in-situ applications in comparison with two-part approach (i.e., involving the use of alkali-activator solutions). The present study compares the one-part and conventional two-part mixing methods with two aluminosilicate precursors, metakaolin and ground granulated blast-furnace slag, using identical mix designs (in terms of molar ratios of SiO2, Al2O3, and Na2O) with both preparation methods. The results revealed that using one-part mix delays the setting time, increases the heat of reaction, decreases the shrinkage, and reaches between 80 and 85% of the compressive strength of the two-part mix. In addition, scanning electron microscopy, thermogravimetric analysis, and X-ray diffraction analysis showed no major differences between one- and two-part. However, energy-dispersive X-ray spectroscopy and magic angle spinning nuclear magnetic resonance experiments indicated that the extent of reaction in two-part alkali-activated mixes is higher than for one-part. Graphical Abstract

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Several studies explore optimal molar oxide ratios for metakaolin geopolymer production. However, there is not a consensus on the optimal mix, and within similar range large differences in compressive strength are reported, and consequently in the overall performance. Hence, the present work selects a specific molar oxide ratio that leads to strengths above 30 MPa (SiO2/Al2O3 ratio of 3.19, a Na2O/Al2O3 of 1.00, and a water-to-solids ratio of 0.52), and investigates the individual effect of the sodium-based activators (NaOH and Na2SiO3) and the water content on fresh and hardened properties of metakaolin geopolymers. The tested properties include the rheology, setting time, mass loss, shrinkage, density and compressive strength. The test results show that an increase of water content (water-to-solids > 0.52) and increase of NaOH (Na2O/Al2O3 > 1.03) have the largest impact, showing a detrimental effect on both fresh and hardened properties. Moreover, the best results are obtained when using molar ratios of SiO2/Al2O3 at 3.14, Na2O/Al2O3 at 0.97 and a water-to-solids ratio of 0.51, which is within the range of optimum molar ratios from previous studies. The tests are further supplemented by Thermogravimetric analysis/Differential scanning calorimetry (TGA/DSC), scanning electron microscopy (SEM), and X-ray diffraction (XRD).