Microstructural insights of geopolymer mortar using binary blended sustainable fine aggregates

The socio-economic growth of a nation depends heavily on the availability of adequate infrastructure, which relies on essential materials like river sand (RS) and cement. However, the rising demand for RS, combined with its excessive extraction causing ecological damage, and its increasing cost, has raised significant concerns. At the same time, the production of cement contributes significantly to environmental damage, especially through CO 2 emissions. In this scenario geopolymer technology has emerged as a sustainable alternative to cement, offering environmental benefits and reducing the carbon footprint of construction materials. This study investigates the impact of replacing RS with copper slag (CS) and laterite soil (LS) in geopolymer mortar (GM) on key properties such as setting time, flowability, compressive strength, and microstructure. The results showed that as LS content increased, setting time and flowability decreased considerably, while increasing CS content caused a reduction in these values. Unlike the other observed parameters, the compressive strength values showed no distinct upward or downward trend. Moreover, the microstructural analysis, including SEM, EDS, XRD, FTIR, TGA and BET, provided valuable insights to support the observed results across various mix designs. Overall, the findings highlight that optimised binary blends of CS, LS and RS not only improved the compressive strength but also enhanced the microstructural characteristics of geopolymer mortar, reinforcing their potential as sustainable and high-performance alternatives to conventional fine aggregates. • Binary mixes of RS, LS, and CS improve GM properties and promote sustainability. • CS enhances GM flowability, strength, and microstructural compactness. • LS serves as an effective alternative to RS for producing sustainable GM. • R6C4 mix achieved a 63.7% higher compressive strength than R10 mix. • Microstructural analysis confirms dense gel formation in CS-based GM mixes.