Mechanical Properties and Microstructure of Alkali-Activated Soda Residue-Blast Furnace Slag Composite Binder

This study prepared an alkali-activated soda residue (SR)-blast furnace slag (BFS) composite binder by adding a large amount of SR to the alkali-activated material system. Considering many factors, such as the Na2O content, ratio of SR to BFS and the water-binder ratio, the variation patterns in the new binder's mechanical properties and its micro-evolution mechanisms were assessed. The results show that the compressive strength first grew and then dropped with the Na2O content, with an optimal level at 3.0%. At this level, the strength values of the 3d and 28d samples were 10.5 and 27.8 MPa, respectively, exceeding those in the control group without Na2O by 337.5 and 69.5%, respectively. As the Na2O admixture increased from 0 to 3%, the fluidity of the mortar decreased from 156 mm to 127 mm due to the high frictional resistance caused by the faster generation of hydration products, and the high water absorption of SR also led to reduced fluidity. The new binder's hydration process mainly generated C-(A)-S-H gel, ettringite (ET), hydrocalumite (HC), calcium hydroxide (CH), and other crystalline hydrates. A 3% Na2O content inhibited the ET growth but significantly promoted the formation of uniformly distributed C-(A)-S-H gel and HC. Crystals grew in the pores or were interspersed in the gel, filling microcracks and significantly increasing the structure density and strength. Excessive Na2O (>3%) could promote the generation of non-uniformly distributed gel, producing more macropores in the matrix and reducing its strength. Additionally, the increased SR content was not conducive to C-(A)-S-H gel formation, but significantly promoted ET formation, which would inhibit strength development. This study provides a theoretical basis for replacing cement with this new binder in pavement bricks and other unreinforced products.