Reactivity Assessment of Diverse Aluminosilicate Wastes in Metakaolin-Based Alkali-Activated Binders

Abstract

Highlights Comparative cementing activity of five industrial wastes was assessed in alkali-activated binders. Float-glass polishing sludge showed the best performance (~25 MPa at 10 wt% addition), ahead of both bottom and fly ash. Compressive strength was correlated with crystallinity and Si/Al molar ratio. XRD, FT-IR and SEM supported the classification of wastes according to cementing activity. The findings support sustainable waste valorization in alkali-activated materials. Abstract The development of carbon-neutral construction materials has stimulated interest in alkali-activated systems for the valorization of industrial non-hazardous waste. This study proposes an original comparative approach to assess the cementing reactivity of several wastes, including black and white fly ash, bottom ash, fine glass dust, and float-glass polishing sludge, through their use as partial replacements for metakaolin (MK). Formulations containing 5–50 wt% of fine waste powders (<45 μm) were prepared and mechanically compared with a reference MK-based geopolymer. Formulations containing waste additions to the reference geopolymeric paste were also evaluated to investigate their role as aggregates/fillers. Mechanical testing identified float-glass polishing sludge as the most reactive precursor, achieving a compressive strength of 25 MPa at 10 w% addition, compared with 16 MPa for the reference material. Bottom ash and black and white fly ash reached approximately 19–21 MPa at 5–10% replacement or addition. Conversely, bottom ash at substitution levels above 5% reduced mechanical performance owing to its high crystallinity and unfavorable Si/Al molar ratio. Microstructural characterization by XRD, FT-IR, density measurements, and SEM was correlated with the observed cementing activity. These results provide a basis for performance-based design criteria aimed at the sustainable valorization of locally available industrial by-products in alkali-activated materials.