Hydration product phase evolution and mortar strength development in alkali-activated slag and fly ash systems

Alkali-activated geopolymer materials, derived predominantly from industrial byproducts such as fly ash and slag, represent a sustainable alternative to Portland cement for applications including anti-seepage grouting, road construction, and high-strength concrete. This study systematically investigates the hydration behavior of slag and fly ash activated by NaOH and Ca(OH)₂ at dosages of 4%, 6%, and 8%, with the constraint that the initial setting time is ≥ 45 min and the final setting time is ≤ 600 min. The mechanical properties of the resultant mortar systems were evaluated using standardized strength testing (ISO method) at curing ages of 3, 7, and 28 days. The phase composition and microstructural evolution of hydration products were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), backscattered electron image analysis (BSE-IA), and isothermal calorimetry. These analytical techniques provided comprehensive insights into the morphology, phase distribution, porosity, and hydration kinetics of the reaction products. The results revealed distinct activator-dependent reactivity trends: NaOH demonstrated higher efficiency in activating slag, whereas Ca(OH)₂ was more effective in promoting the hydration of fly ash. Optimal hydration was achieved with 8% NaOH for slag and 6% Ca(OH)₂ for fly ash, leading to enhanced reaction completeness, increased hydration product formation, denser pore structures, and significantly improved mechanical properties. Alkali-activated slag exhibited substantially greater strength enhancement than fly ash. The 28-day compressive strengths reached 35.94 MPa and 6.65 MPa for slag- and fly ash-based mortars, respectively, with corresponding flexural strengths of 10.23 MPa and 1.92 MPa. These findings demonstrate that the properties of alkali-activated geopolymer materials can be effectively tailored through the strategic selection of alkaline activator type and dosage. This study provides both theoretical insights and technical guidance for the development of sustainable alkali-activated geopolymer materials in construction applications.