Strength Performance and Microstructures of Alkali-Activated Metakaolin and GGBFS-Based Mortars: Role of Waste Red Brick Powder Incorporation

Abstract

Excessive use of natural resources and environmental concerns are key issues motivating the recycling of waste materials in the construction industry to minimize landfill problems. Free cement binders such alkali-activated binders have emerged as a prospective alternative to ordinary Portland cement, wherein diverse industrial, agriculture, and by-product waste materials have been converted as valuable spin-offs. Annually, tens of millions tons of red brick wastes are generated, which leads to several environmental problems. Thus, waste red brick powder (WRBP) was used as binder or a fine aggregate (silica sand) substitute to prepare some new types of alkali-activated mortars (AAMs). These mortars contained ground blast furnace slag (GGBFS) and metakaolin (MK) with various levels of WRBP (0, 15, 30, and 45%) as a substitute for silica sand. The prepared AAMs were cured at 300 °C, 600 °C, and ambient temperature. All the specimens were tested to determine the effects of various WRBP contents on the workability, strengths, and microstructures of the designed AAMs. The workability of the fresh AAMs was considerably dropped due to the incorporation of WRBP as binary binder or fine aggregate replacement. In addition, AAM containing 15% of WRBP as GGBFS and MK replacement displayed a significant improvement (by 30.7%) in the strength performance. However, the increasing content of WRBP to 30% and 45% significantly led to a decrease in compressive strength from 49.9 MPa to 44.7 and 34.2 MPa, respectively. Overall, the mortars’ strength was increased with the increase in WRBP contents from 0 to 45% as sand substitute. Conversely, the mortars strength was reduced with the increase in curing temperatures. The microstructure analyses of the studied mortars revealed an appreciable enhancement of the geopolymerization process, gels formulation, and surface morphology, leading to an improvement in their compressive and flexural strength characteristics. It was asserted that high-performance mortars with customized engineering properties can be designed via the inclusion of WRBP into alkali-activated MK-GGBFS mixes.