Optimizing Alkali-Activated Mortars with Steel Slag and Eggshell Powder

The cement industry is known for being highly energy-intensive and a significant contributor to global CO2 emissions. To address this environmental challenge, this study explores the potential of using the waste materials of steel slag (SS) and eggshell powder (ESP) as partial replacements for cement in alkali-activated mortars (AAMs) production, activated by NaOH and Na2SiO3. Mortar samples are prepared with 50% of ordinary Portland cement (OPC) as part of the total binder, and the remaining 50% is composed of ESP, incrementally replaced by SS at levels of 10%, 20%, 40%, and 50%. The activation process was performed with an 8% NaOH concentration and a silica modulus of 2. Key findings include that the workability of AAMs decreased with increasing SS content, requiring admixtures like superplasticizers or additional water to maintain workability. At 50% SS replacement, the water consistency and slump flow values were 32.56% and 105.73 mm, respectively, with a setting time reduction of approximately 36%, losing plasticity within 2 h. Both absorption capacity and porosity decreased as SS content increased from 10% to 50% of ESP. Additionally, the bulk density, compressive strength, and uniformity of the hardened mortar samples were enhanced with higher SS content, achieving maximum compressive strength (28.53 MPa) at 50% SS replacement after 56 days of curing. Furthermore, OPC-based AAMs incorporating SS and ESP demonstrate good resistance to sulfate attack and thermal heating. Microstructural analysis reveals the presence of C–S–H, C–A–S–H, and N–A–S–H phases, along with minor amounts of unreacted particles, and the microstructure shows a dense, highly compacted, and homogeneous morphology. These findings suggest that replacing eggshell powder with up to 50% steel slag enhances the hardened properties of AAMs. Further research is recommended to explore cement-free alkali-activated granular ground blast furnace slag (GGBFS) with ESP for more sustainable construction solutions.

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