A Cost-Effective Slag-Based Mix Activated with Soda Ash and Hydrated Lime: A Pilot Study

Abstract

The present study explores a cost-effective method for using activated ground granulated blast furnace slag (GGBFS) and silica fume (SF) as cement substitutes. Instead of activating them with expensive alkali solutions, the present study employs industrial-grade powdered sodium aluminate (SA) and hydrated lime (HL) as activators, reducing expenses by about 94.5% compared to their corresponding analytical-grade counterparts. Herein, the exclusivity is depicted using less pure chemicals rather than relying on reagents with 99% purity. Two mixing techniques are compared: one involves directly introducing powdered SA and HL, while the other premixes SA with water before adding it to a dry powder mixture of GGBFS, SF, and HL. Microstructural analysis reveals that the initial strength results from various hydrate phases, including calcium–sodium–aluminate–silicate hydrate. The latter strength is attributed to the coexistence of calcium–silicate hydrate, calcium–aluminate–silicate hydrate, and sodium–aluminate–silicate hydrate, with contributions from calcite and hydrotalcite. The SF content significantly influenced the formation of these gel phases. Thermogravimetric analysis (TGA) reveals phase transitions and bound water related to hydration products. The optimal mix comprises 10% SF, 90% GGBFS, 9.26% HL, and 13.25% SA, with a water-to-solid ratio of 0.45. This approach yields a compressive strength of 35.1 MPa after 28 days and 41.33 MPa after 120 days, hence being suitable for structural construction.