Thermochemical induced mineral formation: A path towards high-strength muscovite-based building materials

• High-strength RM-based mortar was prepared using the TIMF process. • TIMF includes transforming RM/LP into other minerals with different compositions. • Alkali-rich waste glass plays an important role in the TIMF process. Conventionally, alkali-activated calcined clays are produced by pre-treating raw clay minerals through a thermal process to obtain an amorphous aluminosilicate, followed by activation and curing. This multi-step process hinders productivity, particularly in precast building product manufacturing. This work introduces a novel approach, Thermochemical Induced Mineral Formation (TIMF), which involves in-situ thermochemical activation of raw muscovite (RM) within the formulated building mixture, accompanied by the formation of desirable minerals with enhanced mechanical performance. The physical and mechanical performance of the resultant products is primarily influenced by exposure temperature, limestone powder (LP) addition, alkali dosage, and the composition of the induced minerals and amorphous content within the thermally exposed samples. The highest compressive strength (57 MPa) was achieved at 1000 °C, 5 wt% Na 2 O, and 50 wt% LP. This innovative approach aims to streamline the production process by integrating multiple steps into a single operation, potentially reducing energy consumption and improving overall efficiency.