Characterisation and properties of alkali activated pozzolanic materials.

Many of the waste materials produced from modem heavy industries are pozzalans, which develop cementitious properties when finely divided in the presence of free lime. This property allows a potential industrial use for this waste as a cement replacement material in concrete. An example of such a waste material is blast furnace slag from the smelting of iron and steel. The US produces 26 million tons of blast furnace slag annually. Most of the slag is slowly cooled in air and it makes a poor pozzolan. Only 1.6 million tons of the slag is available in the granulated form, which is suitable as a cementitious and pozzolanic admixture. Most European countries are well endowed with coal-fired power stations and this produces fly and bottom ash, flue gas desulphurisation (FGD) gypsum. However, less than 25% of the total ash from power stations has found an industrial use mainly in cement and concrete industry. This creates a massive waste-disposal problem. Disposal of unused fly ash in open tips and ponds, for example, creates pollution problems since the drainage of effluents from the ash in the deposit ponds threaten water supplies by polluting the ground water with traces of toxic chemicals.Recent research has concentrated on the alkali activation of waste pozzolanic materials, especially ground blast furnace slag. This thesis has investigated the alkali activation of low calcium fly ashes. These form very poor pozzolans and the alkali activation of the fly ash offers the opportunity for the large scale use of fly ash. Water glass was selected as a suitable activator for the fly ash. A comprehensive series of tests have been carried out to gain information on the effect of different parameters, such as proportion and composition of the constituent materials, curing conditions and casting methods, in developing high performance construction materials. Laboratory investigations were carried out to determine the following characteristics of alkali activated materials: density, water absorption, apparent porosity and coefficient of saturation, drying shrinkage, compressive creep, compressive, flexural and tensile splitting strength, dynamic modulus of elasticity, accelerated weathering (freeze-thaw cycle) resistance, fire resistance (temperatures up to 600°C), microstructure, macrostructure and investigation of hydration phases by SEM, ED AX, Digital-mapping and X-ray diffraction.The influence of key parameters e.g. slag content, curing method, water/binder ratio and water glass hardener content on the mechanical properties were determined. Optimisation of the alkali-activation of fly ash materials was achieved by blending this with other pozzolans such as silica fume and slags. Mechanical properties were further improved by using moulding pressures and by thermal treatment. The use of short fibre reinforcements was investigated to overcome microcracking, volumetric deformation and creep in the materials. The free shrinkage and creep of the materials agree with the model developed by Mangat and Azari for fibre reinforced Portland cement composites. Other additives were also investigated to improve workability, frost and water resistance and physical properties of the alkali activated materials. The fundamental relationships between chemical composition, hydration phases,microstructure and engineering properties (strength, durability and stability) of alkali activated materials were investigated. It is clear that strength development is a function of the hydration products developed and these are affected by the mix composition and the curing temperature. The current work found parameters such as the Si/Al ratio, the Ca/Si ratio and the Na20 content to be important. These chemical parameters decide the principal phases in the hydration products formed in alkali activated materials, between calcium silicate hydrate (C-S-H) and zeolite of the form (R[2]0 n Al[2]O[3] x SiO[2] r H[2]O).Overall the thesis shows the great potential of alkali activated materials to produce high strength construction materials. Limitation in the shrinkage of the materials can be overcome by the use of fibre reinforcement. At the end of the thesis limitations and suggestions for further work are made.