One trend in the development of building materials is the partial or complete replacement of traditional materials that have a high carbon footprint with eco-friendly ecological raw materials and ingredients. In the present work, the influence of replacing cement with 10 wt% thermally activated natural zeolite on the structural and physical-mechanical characteristics of cured mortars based on white Portland cement and river sand was investigated. The phase compositions were determined by wavelength dispersive X-ray fluorescence (WD-XRF) analysis, X-ray powder diffraction (PXRD), diffuse reflectance infrared Fourier transformed spectroscopy (DRIFTS), and scanning electron microscopy (SEM), as well as thermogravimetric analysis simultaneously with differential scanning calorimetry (TG/DTG-DSC). The results show that the incorporation of zeolite increases the amount of pores accessible with mercury intrusion porosimetry by about 40%, but the measured strengths are also higher by over 13%. When these samples were aged in an aqueous environment from day 28 to day 120, the amount of pores decreased by about 10% and the compressive strength increased by nearly 15%, respectively. The microstructural analysis carried out proves that these results are due to hydration with a low content of crystal water and the realization of pozzolanic reactions that last over time. Replacing some of the white cement with thermally activated natural zeolite results in the formation of a greater variety of crystals, including new crystalline CSH and CSAH phases that allow better intergrowth and interlocking. The results of the investigations allow us to present a plausible reaction mechanism of pozzolanic reactions and of the formation of new crystal hydrate phases. This gives grounds to claim that the replacement of part of the cement with zeolite improves the corrosion resistance of the investigated building solutions against aggressive weathering.
