Using response surface analysis for the optimization of mechanical strength and microstructure of geopolymers with different SiO2/Al2O3 and SiO2/Na2O ratios

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Abstract The increasing release of gases that cause the greenhouse effect brings the need to develop products that minimize the environmental impact. In the civil construction sector, clinker, the main raw material for cement, releases large amounts of carbon dioxide during production. Thus, research related to geopolymers has stood out due to the lower release of gases into the atmosphere. Geopolymers are materials developed from aluminosilicates activated in a highly alkaline medium through geopolymerization. The compositions were prepared by varying the sodium hydroxide solutions NaOH (5, 7.5, and 10, Mols/L) and the proportions of sodium silicate Na2SiO3 to NaOH (1:2, 1:1 and 2:1) to determine a composition with the best characteristics. The factorial experiments of the type 3² were planned with 2 factors and 3 levels. The materials obtained were analyzed at 7 days of curing at room temperature. With the analysis of the results, it was possible to identify that the variation of the parameters SiO2/Al2O3 and Na2O/SiO2 have a significant influence. The Na2SiO3/NaOH ratio is the most important factor in the strength gain at early age. Compressive strength varied between 4.46 and 41.14 MPa as the smallest and highest SiO2/Al2O3 ratio, respectively.

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Carbonates are primary minerals of the carbonatites and kamafugites sourced from Toro-Ankole geological region of the East African Rift system. Consequently, these materials are silica undersaturated. They are currently utilized as mineral additions in production of Portland pozzolana cements in Uganda. No published work exists to show how their unique composition might affect their pozzolanic performance and other concrete properties. This study investigated the effect of the carbonate minerals in the natural pozzolans and calcination on setting time, standard consistency, workability, soundness, early heat of hydration and strength development of blended cements. Two (2) samples, a carbonatite and a kamafugite sourced from deposits located in the Toro-Ankole geological region of the East African rift system were calcined in a furnace at 825 °C for one hour. The samples were then subjected to XRD analysis for mineralogical composition characterisation and to establish the effect of calcination at 825 °C on mineralogy. Setting time, standard consistency, workability, soundness and strength development were studied following standard procedures for testing blended Portland cements. Calcination led to a gain in compressive strength for both test pozzolans, the kamafugites showing a higher gain in strength than the carbonatite. The higher gain in pozzolanic performance for the kamafugites is likely due to kaolinite, a secondary mineral in the test pozzolan whose pozzolanic reactivity is activated by thermal destabilization. Calcination also led to pacification of the early age properties of cements blended with test carbonatites and kamafugites. The study reveals the carbonate minerals in the test pozzolans as a considered factor in accelerating early hydration of Portland cement. Hydration progression of Portland cement controls the important properties of fresh concrete (workability, setting and paste microstructure), which in turn directly impacts on the strength and durability properties of hardened concrete. Cements blended with carbonate bearing natural pozzolans therefore present interesting perspectives on how paste microstructure composition and durability performance properties might be impacted.

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