Use of Abandoned Copper Tailings as a Precursor to the Synthesis of Fly-Ash-Based Alkali Activated Materials

This study evaluated the feasibility of reusing abandoned copper mine tailings (Cu tailings) as a precursor in the production of fly-ash-based alkali-activated materials (FA-AAMs). Two formulations were developed by combining FA and Cu tailings with a mixture of sodium silicate and sodium hydroxide as alkaline activators at room temperature (20 °C). Formulation G1 consisted of 70% Cu tailings and 30% fly ash (FA), whereas G2 included the same composition with an additional 15% ordinary Portland cement (OPC). The materials were characterized using X-ray fluorescence (XRF), -X-ray diffraction (XRD), field emission scanning electron microscopy with energy-dispersive spectroscopy (FESEM-EDS), and particle size analysis. While FA exhibited a high amorphous content (64.4%), Cu tailings were largely crystalline and acted as inert fillers. After 120 days of curing, average compressive strength reached 24 MPa for G1 and 41 MPa for G2, with the latter showing improved performance due to synergistic effects of geopolymerization and OPC hydration. Porosity measurements revealed a denser microstructure in G2 (35%) compared to G1 (52%). Leaching tests confirmed the immobilization of hazardous elements, with arsenic concentrations decreasing over time and remaining below regulatory limits. Despite extended setting times (24 h for G1 and 18 h for G2) and the appearance of surface efflorescence, both systems demonstrated good chemical stability and long-term performance. The results support the use of Cu tailings in FA-AAMs as a sustainable strategy for waste valorization, enabling their application in non-structural and moderate-load-bearing construction components or waste encapsulation units. This approach contributes to circular economy goals while reducing the environmental footprint associated with traditional cementitious systems.