Geopolymer technology offers a sustainable alternative to energy-intensive cement production, potentially reducing dependence on natural resources and mitigating environmental impact. Silica fumes (SF) are mostly used to enhance the fresh, hardened, and durable performance of geopolymers. However, their influence on geopolymerization may result in the expansion of the geopolymer mortar (GPM) due to reaction with alkaline liquid. In this study, the effect of NaOH concentration, particle size and dosage of SF, alkaline liquid-to-binder ratio, Na2SiO3-to-NaOH ratio, and sand-to-binder ratio on the expansion behavior of a low calcium fly ash (FA)-based GPM was investigated. FA-based GPMs were tested using two distinct SFs with varying particle sizes (SF1 = 9.5 µm and SF2 = 16.2 µm) and two varying dosages of SF (2.5% and 5%). Physical observations of GPMs revealed that NaOH concentration, particle size and dosage of SF are crucial factors that significantly impact the expansion which is concomitant with a reduction in compressive strength. Analytical techniques such as X-ray diffraction (XRD), Rietveld analysis, Fourier transform infrared spectroscopy (FTIR), and Thermo Gravimetric Analysis (TGA) were employed to comprehensively investigate reaction product(s) that led to the expansion of such GPMs. The chemical analysis confirmed the presence of excess analcime in the mortars fabricated by blending SF1 and FA at 12 M NaOH concentration. This study is the first to report the expansion of low calcium FA-based GPMs blended with a SF of particle size 9.5 µm. These findings emphasize the significance of selecting the appropriate SF particle size to prevent expansion and ensure optimal compressive strength in geopolymer applications.
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