Without using strong alkaline solution or ordinary Portland cement, a new structural binder consisting of fly ash and hydrated lime was hardened through an intensified pozzolanic reaction. The main experimental variables are the addition of silica fume and initial thermal treatment (60 °C for 3 days). A series of experiments consisting of mechanical testing (compressive and flexural strength, modulus of elasticity), X-ray diffraction, and measurements of the heat of hydration, pore structure, and shrinkage were conducted. These tests show that this new fly ash-based mortar has a compressive strength of 15 MPa at 91 days without any silica fume addition or initial thermal treatment. The strength increased to over 50 MPa based on the acceleration of the intensified pozzolanic reaction from the silica fume addition and initial thermal treatment. This is explained by a significant synergistic effect induced by the silica fume. It intensifies the pozzolanic reaction under thermal treatment and provides a space filling effect. This improved material performance can open a new pathway to utilize the industrial by-product of fly ash in cementless construction materials.

In the cement industry, utilization of a sustainable binder that has a lower energy consumption and carbon dioxide (CO2) emission than Portland cement is becoming increasingly important. Air lime is a binder that hardens by absorbing CO2 from the atmosphere, and its raw material, hydrated lime, is manufactured at a lower temperature (around 900 °C) than cement (around 1450 °C). In this study, the amount and rate of CO2 uptake by air lime-based materials are quantitatively evaluated under ambient curing conditions of 20 °C, 60% relative humidity, and 0.04% CO2 concentration. In addition, the effects of the water-to-binder ratio (w/b) and silica fume addition on the material properties of the air lime mortar, such as strength, weight change, carbonation depth, and pore structure, are investigated. Unlike hydraulic materials, such as Portland cement, the air lime mortar did not set and harden under a sealed curing condition, however, once exposed to dry air, the mortar began to harden by absorbing CO2. During the first week, most of the internal water evaporated, thus, the mortar weight was greatly reduced. After that, however, both the weight and the compressive strength consistently increased for at least 180 days due to the carbonation reaction. Based on the 91-day properties, replacing 10% of hydrated lime with silica fume improved the compressive and flexural strengths by 27% and 13% respectively, whereas increasing the w/b from 0.4 to 0.6 decreased both strengths by 29% due to the increased volume of the capillary pores. The addition of silica fume and the change in the w/b had no significant impact on the amount of CO2 uptake, but these two factors were effective in accelerating the CO2 uptake rate before 28 days. Lastly, the air lime-based material was evaluated to be capable of recovering half of the emitted CO2 during the manufacture of hydrated lime within 3 months.

Abstract:The objective of this study is to develop and characterize kaolinite clay-based structural mortar. The pozzolanic reaction induced from two mineral additives, i.e., calcium hydroxide and silica fume (SF), and the physical filling effect from SF, were found to be effective on the enhancement of structural properties. Based on several preliminary experiments, 7:3 ratio of kaolinite clay/calcium hydroxide was selected as a basic binder. Then, the amount of SF was chosen as 0%, 7.5%, and 15% of the total binder to consider both the chemical and physical effects. The results showed that compressive strengths of samples with 7.5% and 15% SF are significantly increased by approximately 200% and 350%, respectively, at 28 days compared to the sample without SF. However, based on the results of the sample with 15% SF, it is found that excessive addition of SF causes long-term strength loss, possibly owing to micro cracks. With the careful consideration on this long-term behavior, this suggested new mix design can be further extended to develop sustainable structural materials using natural minerals or waste materials with nonbinding properties.

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To utilize alkali-activated materials widely, this study investigates the effects of an intensified pozzolanic reaction and pore filling by silica fume on various material properties of lime-activated slag mortar. Although ground-granulated blast-furnace slag is classified as a cementitious material, it commonly requires an activator to enhance the performance of structural materials. In the first step of the improvement strategy, slag reaction is activated by hydrated lime. Next, silica fume is added to densify the microstructure by the physical pore filling effect and/or the pozzolanic reaction that additionally forms hydration products. This increased the compressive strength by 18% at 28 days and by 25% at 91 days under ambient curing condition, mainly due to the physical effect. Moreover, elevated temperature curing for three days was highly effective to further improve the strength, and to accelerate strength development. This is because both the physical effect and the chemical reaction are effective at the high temperature curing condition. The conducted microstructural investigation provided the evidence for the intensified pozzolanic reaction and pore filling effect, both of which are closely related to the mechanical properties. It is also found that the use of silica fume positively contributes to the dimensional stability. Since the developed material exhibits high strength (>40 MPa after 14 days) without Portland cement or highly toxic chemicals, it can be practically used as an eco-friendly structural mortar.