Enhancing durability of slag‐based alkali‐activated composites with dunite sand and carbon fiber: Sulfate, freeze–thaw, and thermal resistance optimization

Abstract The replacement of natural river sand with sustainable alternatives is essential to reduce environmental degradation associated with aggregate extraction. In this context, dunite sand (DS), a magnesium‐rich ultramafic mineral, was investigated as an eco‐efficient fine aggregate in thermally cured slag‐based alkali‐activated composites (AACs), in combination with carbon fiber (CF) reinforcement. The study aims to clarify how aggregate substitution and fiber addition interact to control matrix densification, crack‐bridging efficiency, and durability under aggressive conditions. Sixteen mixtures incorporating varying DS (0–100%) and CF (0–1.00%) contents were prepared and cured at 80°C to promote rapid slag activation and microstructural development. Mechanical performance, high‐temperature resistance, sulfate durability, and freeze–thaw behavior were systematically evaluated. The results demonstrate that moderate DS substitution (~25%) significantly improves matrix compactness and interfacial quality through a micro‐filler effect, leading to enhanced strength and durability. CF effectively bridge micro cracks and improve flexural and thermal performance; however, excessive fiber contents impair workability and increase porosity due to fiber clustering. Durability results confirm that optimized DS–CF combinations reduce thermal degradation, limit sulfate‐induced deterioration, and enhance resistance to cyclic freezing. Overall, 25% DS replacement combined with limited CF content (≤0.50%) provides the best balance between mechanical performance and durability. The findings highlight the importance of controlling aggregate–fiber synergy and curing strategy to develop durable, thermally stable, and sustainable alkali‐activated composites for harsh service environments.