The effects of paste volume, water content and precursor blend on consistency, setting time and compressive strength of alkali activated concrete (AAC) produced with fly ash (FA) and ground granulated blast furnace slag (GGBS) have been investigated with the aim of developing a suitable mix design procedure. Paste volumes in the range 30%-33% were found not to influence the compressive strength but did influence the consistency of the mixes. The water-to-solid ratio was found to influence compressive strength and setting time. Increasing GGBS content in the binder blend resulted in an increase of the compressive strength, but higher GGBS content caused also early setting which may be undesirable. A mix design procedure has been developed and has been used to determine the constituent mix proportions for three classes of concretes, i.e. (a) a ready-mix concrete with nominal strength 35 MPa, (b) a typical structural concrete with nominal strength 50 MPa, and (c) a high strength concrete for precast applications with nominal strength 70 MPa. Cost analysis was carried out to compare the AAC with Portland cement concretes with similar properties. Normal strength Portland cement concrete (PC), as typically used in ready mix industry has been shown to be less expensive than AAC. However, alkali activated concrete can be competitively priced for high strength concretes. An empirical step-by-step procedure is presented for selecting trial mix proportions for concretes with a range of consistency values, setting times and cube compressive strengths.

Neat fly ash-based alkali activated binders require high activator dosages and high temperature curing in order to develop satisfactory mechanical properties. Blending ground granulated blast furnace slag (GGBS) with fly ash can give medium to high strengths without the need for high temperature oven curing. An extensive investigation was carried out for understanding the effects of GGBS substitution of fly ash in mortar. GGBS substitution in the mix has an impact on mix proportions, fresh and hardened properties, and microstructure of reaction products. The strength of fly ash/GGBS blends cured at room temperature increased with the increase of GGBS content, whilst setting time showed an opposite trend. Fly ash/GGBS blends required lower activator dosages for obtaining high compressive strength, which has cost and environmental benefits. XRD, FTIR, TGA, and SEM/EDX results confirmed the presence of C-AS -H gel as a reaction product with as low as 20% GGBS content.

The growth of the construction industry worldwide poses a serious concern on the sustainability of the building material production chain, mainly due to the carbon emissions related to the production of Portland cement. On the other hand, valuable materials from waste streams, particularly from the metallurgical industry, are not used at their full potential. Alkali-activated concrete (AAC) has emerged in the last years as a promising alternative to traditional Portland cement-based concrete for some applications. However, despite showing remarkable strength and durability potential, its utilisation is not widespread, mainly due to the lack of broadly accepted standards for the selection of suitable mix recipes fulfilling design requirements, in particular workability, setting time and strength. In this paper, a contribution towards the design development of AAC synthesised from pulverised fuel ash (60 %) and ground granulated blast furnace slag (ggbs) (40 %) activated with a solution of sodium hydroxide and sodium silicate is proposed. Results from a first batch of mixes indicated that water content influences the setting time and that paste content is a key parameter for controlling strength development and workability. The investigation indicated that, for the given raw materials and activator compositions, a minimum water-to-solid (w/s) ratio of 0.37 was needed for an initial setting time of about 1 h. Further work with paste content in the range of 30-33 % determined the relationship between workability and strength development and w/s ratio and paste content. Strengths in the range of 50-60 MPa were achieved.