Up to 100% Replacement of Natural Materials from Residues: Recycling Blast Furnace Slag and Fly Ash as Self-Leveling Cementitious Building Materials

Abstract

The objective of this research is to study the use in the construction industry of recycled slag (SL) and fly ash (FA) using from 0.1 to 5% calcium sulfate (wCS¯). These wastes have been used to make ternary mixture systems and evaluated in terms of technological properties as cementitious materials for building applications. Studying their micro-structure as hydration products, setting times and mechanical properties shows a way to develop new mixtures from high proportion of waste, which are alternatives to the traditional nature ternary systems: Portland cement (PC), calcium aluminate cement (CAC) and calcium sulphate (CS¯). Based on previous work with natural products, the selected SL/FA ratios were 9 and 2.3 and the sulphate contents were 0, 1 and 5%. The water/binder ratio used for these cementitious mixes was 0.4. The specimens prepared for strength determination were prisms of 10 × 10 × 60 mm. The pastes were prepared and cured at 20 °C and 98% relative humidity for 1 day and then either stored at 20 °C at 98% humidity (dry) or immersed in distilled water (wet) for 14 and 28 days. The results showed that both FA and SL mixed with CS¯ produce ettringite after 28 days of setting, and this phase was the main crystalline hydrated product in all mixes. Calcium sulphate stimulates the hydration reactions of the mixes and the strength increases when the CS¯ content is higher due to ettringite formation, while the setting time decreases, as happened in the systems prepared with natural materials.