Early strength and repair characteristics of fly ash-based geopolymer mortar for in-situ application at ambient temperature

There is a growing demand for low-carbon cement alternatives in the construction industry. Zero-cement geopolymer, made from waste materials rich in silica and alumina mixed with alkaline solutions, offers a more sustainable option than traditional cement. However, this type of cement is complex, and further research is needed to improve its stability and performance to match traditional cement, especially for use in construction at ambient temperatures. In that context, the research has been designed in three stages which involve the preliminary study on paste, assessment on mortar properties and finally identification of the potential combination for application purposes. Three molarity (10M, 12M and 14M) with constant B/L ratio of 0.43, SS/SH of 2.5 and superplasticizer of 3% has been investigated on a preliminary stage which involves three ranges of combination which are single binder, binary (FA/GGBS, FA/POFA, FA/MK) and 10% MK addition in ternary combinations. Upon that, the potential geopolymer paste combination and molarity has been identified and were extended to mortar study by modification on sand size has been made in the range of 1.18mm-300 μm (Set A) and 150-75 μm (Set B) in order to suit the application usage. The research concluded that sodium hydroxide concentration of 12M shows compatible chemical reactivity in producing high early strength for the binary family of FA/GGBS. High volume of FA (80-60%) shows the most compatible primary cement whereas POFA and MK are more favorable as a third cement component. Finally, FA-based geopolymer mortar at high volume FA content are concluded for grouting and patching works, with the usage of sand at 75 - 150 μm and 300 μm -1.18mm, respectively.

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