Multi-Variable Optimization of Sustainable Alkali-Activated Mortar with High Waste Concrete Powder Dosage for Enhanced Drying Shrinkage Resistance

This study presents a comprehensive strategy for mitigating drying shrinkage of alkali-activated slag mortar (AASM) with the high-dosage incorporation of waste concrete powder (WCP). Response surface methodology (RSM) coupled with microstructural analysis is used to investigate the synergistic effects of WCP particle size (R), activator modulus (AM), activator content (AC), and water to solid ratio (W/S) on shrinkage behavior and matrix development. The optimized mix—WCP-R = 33.6 µm, AM = 1.23, AC = 6.03%. and W/S = 0.49—exhibits a 120-day drying shrinkage of only 1450.1 µε, significantly lower than that of conventional AASM. Microstructural observations reveal that coarser WCP particles act predominantly as fillers, enhancing stability, whereas finer particles promote gel formation but increase shrinkage. A high AM (1.6) refines the pore structure by reducing large pores (>0.05 µm), while a low W/S (0.46) decreases total porosity to 7.67%, collectively restricting moisture transport. The coexistence of C-(A)-S-H gel and hydrotalcite improves matrix integrity. Notably, this optimized HWAASM achieves a substantially reduced carbon footprint of 180 kg CO2-eq/t, underscoring its significant environmental advantage. The findings advance the understanding of shrinkage mechanisms in high-WCP-AASM and offer an eco-friendly route for valorizing construction waste and developing low-carbon building materials.