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

TL;DR

This pilot study demonstrates a cost-effective method for activating slag and silica fume using industrial-grade soda ash and hydrated lime, achieving substantial strength suitable for structural use while significantly reducing material costs.

Contribution

It introduces a novel, economical activation process using less pure chemicals, with detailed microstructural and strength analysis of the resulting cementitious material.

Findings

Achieved 35.1 MPa strength after 28 days

Optimal mix includes 10% silica fume and specific activator proportions

Cost reduction of about 94.5% compared to pure reagents

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 soda ash (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 pre-mixes 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 (CNASH). The latter strength is attributed to the coexistence of calcium-silicate hydrate (CSH), calcium-aluminate-silicate hydrate (CASH) and sodium-aluminate-silicate hydrate (NASH), 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-solids 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 suitable for structural construction.