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This paper focuses on the development of high-strength and eco-friendly one-part (i.e., dry-mix) alkali-activated mortar with ground granulated blast furnace slag as the main precursor. In addition to slag, phyllite dust and silica fume were used as co-binders in binary and ternary blends to improve mechanical properties. Particle packing optimization was employed for the mix proportioning to achieve a compact matrix skeleton. The results revealed that a 10% increase in mortar strength was gained after adjusting the particle packing and an additional 20% increment was observed after blending the slag with other mineral admixtures. Ternary blend with all three binders achieved a mortar compressive strength value of 145 MPa (at 28 d age), which is the highest strength reported in one-part alkali-activated materials. Additionally, ternary blends present potential economic benefits because of their ability to replace slag with lower-cost industrial side streams.

Sodium silicate powders with different SiO2/Na2O (silica modulus) were characterized by solubility rate, pH, and chemical structure (by 29Si MAS-NMR) and compared in the preparation of one-part (or dry-mix) alkali-activated blast furnace slag mortar. The low SiO2/Na2O indicated the beneficial presence of less-polymerized silica (Q1 and Q2 Si environments) and thus faster dissolution. Consequently, using sodium silicates with SiO2/Na2O of 0.9, 2.1, and 3.4 resulted 28 d compressive strengths of 103, 80, and 2 MPa, respectively, with increasing setting time and decreasing heat release in isothermal calorimetry. Adjustment of activator SiO2/Na2O from 2.1 or 3.4 to 0.9 by adding NaOH powder resulted increased or decreased mechanical properties of mortar, respectively, depending on the initial silica modulus. These properties were not, however, similar to those obtained with sodium silicate having SiO2/Na2O of 0.9 originally. Depending on the case, the added NaOH can be consumed for dissolving sodium silicate activator, slag, or the forming (C,N)-(A)-S-H gel.