Evolution of Mechanical Properties, Mineral Crystallization, and Micro-Gel Formation in Alkali-Activated Carbide Slag Cementitious Materials

For efficient utilization of carbide slag (CS) waste to high-value building materials, in this study, CS and ground granulated blast furnace slag (GBFS) were used as primary raw materials to prepare alkali-activated cementitious systems under strong alkaline excitation. Multiscale mechanisms involving macroscopic mechanical property development were investigated. Microstructural characterization elucidated how raw material composition affected mineral crystal formation and transformation while revealing enhancement mechanisms governing micro-gel network structure formation and evolution dynamics. The results indicate that excessive calcium components coupled with deficient Si–Al sources in CS severely inhibit the formation of C-S-H and C-A-S-H gel phases, consequently impeding mechanical performance development. Also, GBFS incorporation offsets inherent silicon–aluminum deficiencies. Active [SiO4]4− and [AlO4]5− released from GBFS drive polycondensation reactions toward advanced polymerization states. Compressive strength has a nonlinear growth kinetics characterized by rapid initial ascent, followed by asymptotic plateauing as GBFS content increases. Optimal comprehensive performance emerges at a 5:5 GBFS-to-CS mass ratio, where 28d compressive strength reaches 47.5 MPa.