A comparative cradle-to-gate life cycle assessment of geopolymer concrete produced from industrial side streams in comparison with traditional concrete

Consequences of omitting some important factors in the environmental analyses of commercial sodium silicate/sodium hydroxide use for alkaline activation in the light of comparison with cement-based composites

Alkali-activated materials (AAMs) based on various waste precursors were considered mostly as a sustainable alternative to Portland cement-based composites to date. However, a narrow focus on carbon dioxide savings in the environmental assessment of AAMs may not be sufficient to achieve a truly sustainable solution. Therefore, this paper provides a detailed insight into midpoint impact categories related to the production of AAMs based on waste precursors and conventional activators, as compared with common cement-based materials. The obtained results point to a higher environmental load of AAMs in several categories, such as ozone layer depletion, primary resource consumption, and terrestrial and aquatic ecotoxicity. In a hypothetical scenario, it is demonstrated that 10 % replacement of global concrete production by AAMs may result in notably increased emissions of ozone depletion substances (+35 %) and damage to the aquatic environment (+ 40 %). The risk for human health can then be higher. As for the aquatic environment, eutrophication can also lead to a significant increase in indirect emissions of CH4 and N2O having a high impact on the greenhouse effect. Hence, the importance of robust interdisciplinary research in the environmental assessment of AAMs should be emphasized, together with the need to use alternative alkaline substances, which would be more environment-friendly than conventional activators.

Alkaline Activation of Binders: A Comparative Study

Binders formulated with activated alkali materials to replace Portland cement, which has high polluting potential due to CO2 emissions in its manufacture, have increasingly been developed. The objective of this study is to evaluate the main properties of activated alkali materials (AAM) produced by blast furnace slag, fly ash, and metakaolin. Initially, binders were characterized by their chemical, mineralogical and granulometric composition. Later, specimens were produced, with molarity variation between 4.00 and 5.50, using the binders involved in the research. In preparing the activating solution, sodium hydroxide and silicate were used. The evaluated properties of AAM were consistency, viscosity, water absorption, density, compressive strength (7 days of cure), calorimetry, mineralogical analysis by X-ray diffraction, and morphological analysis by scanning electron microscopy. The results of evaluation in the fresh state demonstrate that metakaolin has the lowest workability indices of the studied AAM. The results observed in the hardened state indicate that the metakaolin activation process is optimized with normal cure and molarity of 4.0 and 4.5 mol/L, obtaining compressive strength results after 7 days of curing of approximately 30 MPa. The fly ash activation process is the least intense among the evaluated binders. This can be seen from the absence of phases formed in the XRD in the compositions containing fly ash as binder. Unlike blast furnace slag and metakaolin, the formation of sodalite, faujasite or tobermorite is not observed. Finally, the blast furnace slag displays more intense reactivity during thermal curing, obtaining compressive strength results after 7 days of curing of around 25 MPa. This is because the material's reaction kinetics are low but can be increased in an alkaline environment, and by the effect of temperature. From these results, it is concluded that each precursor has its own activation mechanism, observed by the techniques used in this research. From the results obtained in this study, it is expected that the alkaline activation process of the types of binders evaluated herein will become a viable alternative for replacing Portland cement, thus contributing to cement technology and other cementitious materials.

Strength, porosity and life cycle analysis of geopolymer and hybrid cement mortars for sustainable construction

Owing to the application of industrial wastes, geopolymers are generally regarded as a sustainable alternative to traditional construction materials. However, their lack of adoption on the industrial scale demands detailed investigations. This study conducts a comparative analysis of the compressive strength of different geopolymer and hybrid cement mortars with varying proportions of sodium hydroxide (from 5 to 25 wt%) and ordinary Portland cement (OPC) (from 15 to 35 wt%), respectively. The porosity of all designed mixtures was also analyzed using X-ray computed tomography (XCT) and water absorption tests. ReCiPe 2016 Midpoint (H) method was used for the Life cycle analysis of the geopolymer and hybrid cement mortars. Multi-criteria decision making (MCDM) approach was used to assess the sustainability potential of the designed mixtures based on compressive strength, porosity and overall environmental impact. Experimental results revealed that the increase in sodium hydroxide in geopolymer mortars up to 15 wt% offered its maximum compressive strength. Superior compressive strength was obtained at 35 wt% of OPC in hybrid cement mortars due to the formation of more C-S-H, C-A-S-H and N-A-S-H gels which fill up the voids and pores. Analysis of the macro and micro-porosity revealed that hybrid cement mortars yield denser structure than geopolymer mortars. Life cycle analysis based on 8 distinct impact categories showed that hybrid cement mortars outperform the geopolymers in all impact categories except 'mineral resource scarcity'. However, the overall environmental impact assessment using the 'coefficient of performance' depicts that hybrid cement mortars offer a significantly lower environmental burden than geopolymers. MCDM analysis shows that hybrid cement mortar with 5 wt% of sodium hydroxide and 35 wt% of OPC is the best choice for construction applications. This idea of sustainable hybrid cement mortar will be helpful for the construction industry to limit the environmental impact without compromising their structural performance.

Properties, Microstructure Development and Life Cycle Assessment of Alkali-Activated Materials Containing Steel Slag under Different Alkali Equivalents

To improve solid waste resource utilization and environmental sustainability, an alkali-activated material (AAM) was prepared using steel slag (SS), fly ash, blast furnace slag and alkali activators in this work. The evolutions of SS content (10-50%) and alkali equivalent (4.0-8.0%) on workability, mechanical strength and environmental indicators of the AAM were investigated. Furthermore, scanning electron microscopy, X-ray diffraction and nuclear magnetic resonance techniques were adopted to characterize micromorphology, reaction products and pore structure, and the reaction mechanism was summarized. Results showed that the paste fluidity and setting time gradually increased with the increase in SS content. The highest compressive strength was obtained for the paste at 8.0% alkali equivalent due to the improved reaction rate and process, but it also increased the risk of cracking. However, SS was able to exert a microaggregate filling effect, where SS particles filling the pores increased the structural compactness and hindered crack development. Based on the optimal compressive strength, global warming, abiotic resource depletion, acidification and eutrophication potential of the paste are reduced by 76.7%, 53.0%, 51.6%, and 48.9%, respectively, compared with cement. This work is beneficial to further improve the utilization of solid waste resources and expand the application of environmentally friendly AAMs in the field of construction engineering.

Recycling waste dolomite powder in cement paste: Early hydration process, microscale characteristics, and life-cycle assessment

Waste dolomite powder (WDP) is a byproduct obtained from dolomite quarries during the preparation of dolomite products. To study the re-utilisation of WDP, an eco-friendly cement-based material was prepared using WDP as a micro-aggregate. The effects of WDP on the early hydration process, microscale characteristics, and life-cycle assessment of cement paste are discussed in this study. The isothermal calorimetry results showed that the incorporating WDP in cement paste accelerated the early hydration process of cement according to the degree of reaction. In this case, the setting time of the cement pastes with WDP was shortened, and the early compressive strength was significantly improved. The results of X-ray diffraction and scanning electron microscopy analysis at early curing ages (1 and 3 d) showed changes in the peak intensity of ettringite and portlandite and a denser microstructure. Mercury intrusion porosimetry tests showed that the middle and large capillary pores were refined by the nucleation and filling effects of WDP. Based on environmental and economic evaluations, the utilisation of WDP reduced energy consumption, CO2 emissions, and economic costs. Compared to the sample without WDP, the energy consumption, CO2 emissions, and economic cost indices were 42 %, 42.69 %, and 39.4 % lower, respectively. Our results may provide valuable references for the re-utilisation of WDP in low-carbonation cement-based materials.

Experimental and Numerical Investigation of the Mechanical Properties of a Fiber-Reinforced Geopolymer Mortar Blast Resistant Panel

Geopolymer materials have excellent properties such as high strength, low thermal conductivity, fire resistance, acid and alkali resistance, and low carbon emissions. They can be used as protective engineering materials in places with explosion risks. At present, the common composite blast resistant panel is in the form of a sandwich: the outer layer isgalvanized steel plate, and fiber cement board or calcium carbonate board is used as the inner layer material, as these boards have the advantages of easy installation, good fire resistance, and explosion resistance. This study investigates the effect of adding different types of fibers to geopolymer mortar on the mortar's basic mechanical properties, such as compression strength, bending strength, and impact resistance. The explosive resistance of the fiber-reinforced geopolymer mortar blast resistant panels was evaluated through free-air explosion. In this paper, experimental procedures and numerical simulation have been performed to study the failure modes, maximum deflection, and dynamic response of the fiber-reinforced geopolymer mortar blast resistant panel under free-air explosion. The research results can provide a reference for the design and production of blast resistant panels.