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Calcium carbide residue (CCR) is the end-product of production of acetylene gas for the applications such as welding, lighting, ripening of fruits, and cutting of metals. Due to its high pH value, disposing of CCR as a landfill increases the alkalinity of the environment. Therefore, due to its high calcium content, CCR is mostly blended with other pozzolanic materials, together with activators as binders in the cement matrix. In this study, cement was partially substituted using CCR at 0%, 7.5%, 15%, 22.5% and 30% by weight replacement, and nano silica (NS) was utilized as an additive by weight of binder materials at 0%, 1%, 2%, 3% and 4%. The properties considered were the slump, the compressive strength, the flexural strength, the splitting tensile strength, the modulus of elasticity, and the water absorption capacity. The microstructural properties of the concrete were also examined through FESEM and XRD analysis. The results showed that both CCR and NS increase the concrete’s water demand, hence reducing its workability. Mixes containing up to 15% CCR only showed improved mechanical properties. The combination of CCR and NS significantly improved the mechanical properties and decreased the concrete’s water absorption through improved pozzolanic reactivity as verified by the FESEM and XRD results. Furthermore, the microstructure of the concrete was explored, and the pores were refined by the pozzolanic reaction products. The optimum mix combination was obtained by replacing 15% cement using CCR and the addition of 2% NS by weight of cementitious materials. Therefore, using a hybrid of CCR and NS in concrete will result in reduction of cement utilization in concrete, leading to improved environmental sustainability and economy.

For the same concrete quality, different types of coarse aggregates may result in different mechanical properties. This paper presents a study on the effect of aggregate types on the mechanical properties of two concretes, namely, geopolymer concrete (GP) and traditional Portland cement (TC) concrete. The mechanical properties were investigated through several large-scale tests. Moreover, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and laser scanning microscope (LSM) images were obtained to study the microstructure of tested mixes. The results revealed that the aggregate type has different effects on the mechanical properties of TC and GP, as they were behaving opposite to quartz and limestone aggregates. Microstructure analysis further confirmed the growth of well-bonded regions between the paste and aggregate in the GP with limestone aggregates, and the formation of several weak interfacial zones in concrete mixtures made with quartz aggregates. It was concluded that the mechanical properties of GP are very sensitive to the stiffness of aggregate, concentrations of stress, and the physical and chemical reactions occurring in the interfacial transition zone which may lead to improved or weakened bond strength between paste and aggregates.

Alkali-activated fly ash (AAFA) is usually cured at elevated temperature, which limits its wide field applications. However, several studies have shown that properties of AAFA cured at ambient temperature can be significantly improved by incorporating different cementitious additives. This research investigated the impact of substituting a small portion of fly ash with different potential cementitious additives such as slag, metakaolin, and silica fume on various properties of AAFA mixtures at ambient curing conditions. Toward that end, several experimental observations including workability, geopolymerization heat released, compressive strength, Young’s modulus, electrical resistivity, chloride permeability, and pore structure distribution were made. The effects of alkaline solution concentration combined with the different chemical compositions on mechanical properties and permeability characteristics were also investigated. An ordinary Portland cement was also included in the testing program as a comparative reference. Test results showed that the AAFA mixtures exhibited lower heat as compared to ordinary Portland cement mixture, and the results of heat evolution were in line with early-age strength development. The inclusion of metakaolin resulted in a significant improvement in the early strength and stiffness. The inclusion of slag led to the improvement of the mechanical and permeability properties of AAFA cured at ambient temperature, and the effect of sodium silicate (SS) to sodium hydroxide (SH) solution ratio was found to be more profound when the slag was used as an additive. Incorporating silica fume in the AAFA mixtures decreased the mechanical properties and increased the volumetric percentage of large capillary pores.

This paper presents a multiscale experimental study on the influence of different Na2O/SiO2 molar ratios on the mechanical and microstructural characteristics of the aggregate-paste interphase in fly ash-based geopolymer mixtures. By analyzing the scanning electron microscope images, the solid phases present in the microstructure were identified, and the frequency of occurrence of each phase was quantified. In addition, the porosity and pore size distribution of geopolymer specimens were measured by mercury intrusion porosimetry. By conducting nanoindentation tests on a large array of indentations and subsequent statistical analysis of the test results, the elastic moduli of individual phases were extracted. The bond behavior between aggregate and paste was also investigated by conducting the three-point bending test of single edge notched beam specimens. Integration of test results in different length scales showed that interphase region generates more sodium aluminosilicate hydrate (i.e., N-A-S-H) gel than the adjacent paste region regardless of the Na2O/SiO2 ratios used in this study. In addition, the mixture prepared with the higher Na2O/SiO2 molar ratio exhibited more N-A-S-H gel in the interphase zone, which led to increased bonding strength between aggregate and paste.

Effective properties and structural performance of cementitious mixtures are substantially governed by the quality of the interphase region because it acts as a bridge transferring forces between aggregates and a binding matrix and is generally susceptible to damage. As alternative binding agents like alkali-activated precursors have obtained substantial attention in recent years, there is a growing need for fundamental knowledge to uncover interphase formation mechanisms. In this paper, two different types of binding materials, i.e., fly ash-based geopolymer and ordinary portland cement, were mixed with limestone aggregate to examine and compare the microstructures and nanomechanical properties of interphase region. To this end, microstructural characteristics using scanning microscopies, nanomechanical properties by nanoindentation tests, and spatial mapping of chemical contents based on the energy dispersive spectroscopy were integrated to identify and investigate the interphase region formed by the case-specific interactions between the matrix materials and limestone. The integrated microstructural-nanomechanical-chemical approach was effective to better understand links between material-specific properties of cementing phases. More specifically, the fly ash-based geopolymer paste was usually well bonded to the aggregate surface with a rich formation of N-A-S-H gel, while interfacial debonding was often observed between aggregate surface and paste in ordinary portland cement concrete. However, when a good bonding between aggregate and paste is formed, interphase region in PCC did not show any considerable difference in nanomechanical properties compared to the bulk paste.

Approaches to improve the early strength of geopolymer mortar were studied in order to apply it to a fast-tack concrete pavement repair. The effects of modifying the molar ratio of silicon dioxide/sodium oxide (SiO2/Na2O) of the alkaline solution in a conventional geopolymer mixture and the addition of calcium aluminate cement and slag were studied. The early strength measured in the experiments was at curing times of 8 and 24 h, which are typically construction controlling times for pavement repair. It was found that a molar ratio of silicon dioxide/sodium oxide of 1·0 gave the shortest curing time and the highest early strength after 24 h. Adding calcium aluminate cement was found to reduce the curing time, but decrease the early strength. Slag substitution helped workability, but reduced the early strength at 8 and 24 h. Durability was also tested for the purpose of finding an economical pavement repair solution. A freeze–thaw durability experiment of the suggested metakaolin-based geopolymer concrete was conducted. It was found that a mix with a silicon dioxide/sodium oxide molar ratio of 1·0 produced higher durability than a mix with a silicon dioxide/sodium oxide molar ratio of 1·4. The geopolymer concrete mix with slag showed less weight loss than the other mixes.

This paper presents a two-way linked multiscale method that is integrated with nanomechanical tests and a cohesive zone fracture model to investigate highly heterogeneous cementitious mater...

In order to use geopolymer mortar as a pavement repair material, a splitting test and a slant shear test are performed to characterize the bond strength of the geopolymer and conventional cement mortar interfaces. Effect of curing time, degradation of the cement mortar under different acid conditions on the bond strength of geopolymer with conventional cement mortar, and comparison of the metakaolin geopolymer with other pavement repair materials are analyzed. It was found that curing time affects the interface bond strength greatly. Metakaolin geopolymer reaches 80% of its 28 day strength in 3 days curing, but shows low strength in 24 h curing. Curing temperature affects the strength of metakaolin geopolymer, however metakaolin geopolymer cured in ambient temperature and the bond strength of 3 days curing through splitting and slant shear tests reaches 3.63 MPa and 16.32 MPa, respectively. Degradation of cement mortar negatively affects the bond strength of geopolymer and conventional cement mortar. Possibility of using metakaolin geopolymer as a repair material is discussed by comparison of this experimental result with these of other repair materials.