Reinventing the structural fired clayey bricks through the geopolymerisation of laterites

Fired clayey products have been successfully used as structural materials for many engineering applications as building and construction all around the world. In the tropical area, however, the most available raw clayey materials are laterites (kaolinite with associated iron minerals). The kaolinite present in the laterites based concretes is amorphous or metastable prompt to be activated with alkaline solution. In this work, the results of the investigations regarding the geopolymerisation of laterites are presented. It was found that in the presence of amorphous silica, the iron minerals of laterites reacts to form low temperature iron silicates with particularly good mechanical properties (15-35 MPa) as the results of the combination of polysialates, ferrosialates and ferrosilicates. Composites obtained can be valorized as products of substitution of structural fired clayey products

Materie prime di origine naturale nel processo di geopolimerizzazione

Geopolymers are inorganic materials prepared via a room temperature treatment (25-120?C) with alkali activation. The main applications of these materials is in the field of building materials, recycle and inertization of waste, restoration. The production and final product is optimised by a careful selection of starting materials, i.e. aluminosilicate powders. In this paper are presented aluminosilicates from natural source, as an example kaolin, clays or volcanic ash. Metakaolin is the most reactive due to its amorphous structure and aluminium coordination; its reactivity is also influenced by its mineralogical origin, morphology of grains, and calcinations method. Volcanic ash present lower reactivity and the better consolidation temperature to obtain mechanically strong materials appears to be around 400?CI materiali geopolimerici sono materiali inorganici ottenuti con consolidamento a bassa temperatura (25-120?C) mediante una reazione chimica in ambiente alcalino. Sono utilizzati per applicazioni ad alta temperatura e strutturali in edilizia, per il riciclo e /o l?inertizzazione di scorie industriali, per il restauro. L?opportuna selezione di materie prime alluminosilicatiche ? alla base dell?ottimizzazione del ciclo produttivo e del prodotto finale. Vengono presentate materie prime di origine naturale, quali il metacaolino, derivato dalla calcinazione del caolino, e le ceneri vulcaniche. Il metacaolino ? la materia prima pi? reattiva grazie alla struttura amorfa e alla coordinazione dell?alluminio: sulla reattivit? influiscono sia la morfologia e le caratteristiche del caolino di origine, sia la metodologia di calcinazione. Le ceneri vulcaniche hanno una minore reattivit? che pu? esser ovviata tramite un consolidamento a circa 400?C portando a prodotti geopolimerici con buone prestazioni meccanich

Advancing the use of secondary inputs in geopolymer binders for sustainable cementitious composites: A review

Because of concerns over the construction industry's heavy use of cement and the general dissatisfaction with the performance of building envelopes with respect to durability, there is a growing demand for a novel class of "green" binders. Geopolymer binders have re-emerged as binders that can be used as a replacement for Portland cement given their numerous advantages over the latter including lower carbon dioxide emissions, greater chemical and thermal resistance, combined with enhanced mechanical properties at both normal and extreme exposure conditions. The paper focuses on the use of geopolymer binders in building applications. It discusses the various options for starting materials and describes key engineering properties associated with geopolymer compositions that are ideal for structural applications. Specific properties, such as compressive strength, density, pore size distribution, cumulative water absorption, and acid resistance, are comparable to the specifications for structures incorporating conventional binders. This paper presents geopolymer binders, with their three dimensional microstructure, as material for structural elements that can be used to advance the realization of sustainable building systems. © 2011 by the authors

Design of inorganic polymer mortar from ferricalsialic and calsialic slags for indoor humidity control

Amorphous silica and alumina of metakaolin are used to adjust the bulk composition of black (BSS) and white (WSS) steel slag to prepare alkali-activated (AAS) mortars consolidated at room temperature. The mix-design also includes also the addition of semi-crystalline matrix of river sand to the metakaolin/steel powders. The results showed that high strength of the steel slag/metakaolin mortars can be achieved with the geopolymerization process which was particularly affected by the metallic iron present into the steel slag. The corrosion of the Fe particles was found to be responsible for porosity in the range between 0.1 and 10 μm. This class of porosity dominated (~31 vol %) the pore network of B compared to W samples (~16 vol %). However, W series remained with the higher cumulative pore volume (0.18 mL/g) compared to B series, with 0.12 mL/g. The maximum flexural strength was 6.89 and 8.51 MPa for the W and B series, respectively. The fracture surface ESEM observations of AAS showed large grains covered with the matrix assuming the good adhesion bonds between the gel-like geopolymer structure mixed with alkali activated steel slag and the residual unreacted portion. The correlation between the metallic iron/Fe oxides content, the pore network development, the strength and microstructure suggested the steel slag's significant action into the strengthening mechanism of consolidated products. These products also showed an interesting adsorption/desorption behavior that suggested their use as coating material to maintain the stability of the indoor relative humidity

Investigation of volcanic ash based geopolymers as potential building materials

Volcanic ash powders from Etna (Italy) and Cameroon were used as the principal source of aluminosilicate to produce geopolymers with the potential for making building products. The volcanic ash was ball milled and reacted with concentrated alkaline solutions for polymerisation and subsequent curing at 75-400 °C for 12-48 h. It was found that the gel was more viscous than a similar gel formed from metakaolin. Geopolymers made from both ashes had bulk densities of 1.7-2.0 g/cm3 and water absorption values of 20-25 %. Their compressive strength values were 25-35 MPa and the bi-axial four-point flexura! strength values ranged from 14-20 MPa. These values increased by 20 % when cured for 21 d after 90 d storage. It was also found that by curing at 200-400 °C the mechanical properties increased. Scanning electron micrographs showed that with thermal curing microcrystalline phases were present along with undissolved crystalline phases. These phases remained bound to the matrix and acted as a filler for strengthening the materials. The Ca, Mg and Fe present as impurities in the volcanic ash formed some of these crystalline phases and did not form any deleterious hydroxide or carbonate phases

Binder chemistry – Low-calcium alkali-activated materials

Early developments in the developments of low-calcium (including calcium-free) alkali-activated binders were led by the work of Davidovits in France, as noted in Chap. 2. These materials were initially envisaged as a fire-resistant replacement for organic polymeric materials, with identification of potential applications as a possible binder for concrete production following relatively soon afterwards [1]. However, developments in the area of concrete production soon led back to more calcium-rich systems, including the hybrid Pyrament binders, leaving work based on the use of low-calcium systems predominantly aimed at high-temperature applications and other scenarios where the ceramic-like nature of clay-derived alkali-activated pastes was beneficial. Early work in this area was conducted with an almost solely commercial focus, meaning that little scientific information was made available with the exception of a conference proceedings volume [2], several scattered publications in other conferences, and an initial journal publication [3]. Academic research into the alkaline activation of metakaolin to form a binder material led to initial publications in the early 1990s [4, 5], and the first description of the formation of a strong and durable binder by alkaline activation of fly ash was published by Wastiels et al. [6-8]. With ongoing developments in fly ash activation, which offers more favourable rheology than is observed in clay-based binders, interest in low-calcium AAM concrete production was reignited, and work since that time in industry and academia has led to the development of a number of different approaches to this problem. A review of the binder chemistry of low-calcium AAM binder systems published in 2007 [9] has since received more than 350 citations in the scientific literature, indicating the high current level of interest in understanding and utilisation of these types of gels

Mullitization behaviour during thermal treatment of three kaolinitic clays from Cameroon: Densificaron, sintering kinetics and microstructure

Three kaolinitic clays from Cameroon were studied for their mullitization behaviour. The three clayey materials were from Ntamuka (TAN), Mayouom (MAY) and Wabane (WAB), all situated in the hills of western Cameroon. X-ray diffraction and thermal, dilatometric and SEM-EDS analyses were used to follow up the phase evolution, sintering kinetics and microstructure of the three materials as a function of temperature (1000-1500°C). Fine powders of each sample were pressed and treated in the above temperature range with the goal to correlate the phase evolution with densificaron parameters (shrinkage, porosity, density and mechanical strength). The nucleation of mullite and the increase of peak intensities were directly correlated to continuous densification and reduction of open porosity as observed under the SEM, The mullitization peak temperatures at 5°C/min were 973°C, 979.1°C, and 983.6°C respectively for TAN, MAY and WAB and - in the same order but at 20°C/min 992.1°C, 997.4°C and 1001.2°C. The mullitization phenomenon, which includes a first step of nucleation and a second of crystal growth, shows an activation energy that varies depending on the nature of sample investigated: the values ranged from 650 to 730 kJ/mol. The microstructure of the sintered products consisted on the elongated secondary mullite (types II and III) interlocking with primary (type I) mullite in a compact matrix with relative amount of glassy phase for MAY and WAB. The morphology of mullite grains in TAN was more different being laiger cuboid grains aggregated with cristobalite to form a compact microstructure. The formation of TiO2 crystals and then Ti-Al (tialite: Al2TiO5) crystals influenced the microstructure of MAY and WAB

Low-temperature alkaline activation of feldspathic solid solutions: Development of high strength geopolymers

Most of the natural solid solutions, as a result of the history of their formation and crystallization, present a fraction of amorphous or metastable materials that may easily be dissolved or activated in alkaline media. In this work, trachyte, granite, pegmatite and sand for comparison are used as principal solid precursors for the design of high strength geopolymers. The particularity of the solid-solution based geopolymers is the high fraction of crystalline phases incongruently dissolved that may react essentially at the surface, thus developing very resistant bonds. While working with 100 wt% of solid solution is almost unrealistic for the production of geopolymers, it was found that 15 to 30 wt% of metakaolin in replacement of the solid-solution powder conducts to low porosity (10 vol.%), high flexural strength (20-30 MPa) and compact microstructure. Preliminary resonance-based mechanical tests showed that the elastic modulus of the investigated samples ranged between 11-15 GPa, as also confirmed by instrumented micro-indentations. It was concluded that a high strength and durable matrix are a result of chemico-mechanical equilibrium of phases contained within the composites including the pore volume and pore-size distribution, which are significant for the life cycle of geopolymer composites

Investigation of the relationship between the condensed structure and the chemically bonded water content in the network of geopolymer cements

The main objective of this work was to investigate the relationship between the condensed structure and the chemically bonded water content in the metakaolin-based geopolymer network. The kaolinite clay used in this work as an aluminosilicate source was transformed to metakaolin by calcination at 700 °C. The powder of the waste glass and the silica fume were used as silica sources for the synthesis of the hardeners. The obtained hardeners were characterized by infrared spectroscopy and MAS-NMR 29Si. The metakaolin and the hardeners were used for producing geopolymers cements. The synthesized products were characterized by X-ray diffractometry, infrared spectroscopy, mercury intrusion porosimetry, scanning electron microscopy, MAS-NMR 29Si and 27Al, thermal analyses (TG and DSC) and compressive strength. The results show that the compressive strength of geopolymer cements using hardener from silica fume and the one from waste glass are 62 and 26 MPa, respectively. The microstructure (SEM observations) geopolymer cements obtained using hardener from silica fume are homogeneous, compact and dense with an average pore diameter around 10 nm. Whereas, the one obtained using hardener from waste glass are heterogeneous and contains larger pores (170 nm). MAS-NMR 29Si and 27Al results show that the specimen obtained using hardener from the silica fume contains more aluminum in four-fold coordination in its network than waste glass geopolymer, GWG. This indicates a higher degree of crosslinking of poly(sialate-siloxo) chains which could lead to a smaller pore sizes and a higher water uptake in the structure of the sample. The amount of chemically bonded water contained in the network of geopolymer cements using hardeners from waste glass and silica fume were 6.82 and 11.23%, respectively, as determined from weigth loss in the range 100-300 °C. All these results indicate that the higher content of chemically bonded water in the network of geopolymer obtained using hardener from silica fume is related to the much smaller average pore size diameter and the hydrophilic character of aluminum, which reveals obviously better mechanical and microstructural properties of the specimen. This could indicate here a higher degree of condensation using silica fume based hardeners for geopolymerisation. Please click Additional Files below to see the full abstract