Commonly used alkali activation precursors such as blast furnace slag and fly ash will soon become less available due to resource competition, and may cease to be produced in certain regions. This limitation in future supply is a main driving force for the investigation of alternative precursor sources, such as non-blast furnace slags and non-ferrous slags, to produce alkali-activated binders. The current study investigates the incorporation of copper slag (CS) and stainless steel slag resulting from electric arc furnace operations (EAFSS) as partial replacements for ground granulated blast furnace slag (GGBFS) in producing alkali-activated materials (AAMs), at paste level. Five binary alkali-activated mixtures with different replacement levels of GGBFS with CS, and three ternary mixtures with both CS and EAFSS as partial and total replacements for GGBFS, are activated by a sodium silicate solution. Replacing GGBFS with CS and EAFSS retards the reaction kinetics, resulting in improved fresh-state properties of the investigated AAMs, better retention of workability and longer setting times. The reaction of alkali-activated 100% CS shows minimal initial exothermic activity until 3.5 h, when a single intense peak appears, representing delayed dissolution and subsequent polycondensation. X-ray diffraction (XRD) data indicate that the main crystalline phases of CS and EAFSS are stable in these alkaline systems; it is the glassy components that react. The use of CS and EAFSS in blended AAMs causes a minor increase in porosity of ~ 1–3% with respect to GGBFS only, and a small reduction in compressive and flexural strengths, although these reach 80 MPa and 8 MPa, respectively, after 28 days, even at a replacement level over 65 wt. %. Conversely, the 100% CS mixture exhibits a one-day compressive strength of 23 MPa, with a negligible increase thereafter. This result agrees with both FTIR and SEM analysis which highlight only minor changes in binder development after two days. It is believed that the unusual behaviour of CS in the investigated mixtures is related to the low availability of calcium in this precursor material.
This paper discusses the design of hybrid alkali-activated binders at ambient temperature, specifically the development of mixes based on ground granulated blast-furnace slag (GGBFS) with calcium aluminate cement (CAC) as an additive, aiming to obtain high early strength binders with optimised Al incorporation, increased crosslinking and degree of polymerisation. The effects of 10 wt% CAC replacement of GGBFS, activated with sodium silicate with varying modulus (SiO2/Na2O molar ratio) or with sodium hydroxide, on fresh and hardened properties are investigated. The inclusion of CAC in GGBFS mixtures activated using sodium silicate results in an unexpected retardation of the polycondensation reactions required to form the main calcium aluminosilicate hydrate gel phase. This is due to incomplete dissolution of the GGBFS precursor, inhibited by the rapid formation of additional reaction products (especially cubic aluminate hydrates, C3AH6) resulting in lowered reaction kinetics, and thus delayed setting and hardening times. For sodium silicate activators, this retarding effect appears to be only slightly dependent on the activator solution modulus. When activating with 4 M NaOH, the retarding effect is reduced, along with the incorporation of CAC in the C-A-S-H gel, increasing the amount of reactive aluminium present in the binder to form a more compact gel product. Increasing the molarity of NaOH solutions results in a similar delay in reaction kinetics. The results suggest the existence of only a limited pH range in which the addition of CAC can promote the formation of a binding gel with enhanced mechanical properties, whilst other factors including the effect of sodium silicate inclusion in CAC systems are still unclear. The typical hydration products of CAC were not detected in this study.
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