Acid Resistance Behaviour of Seawater-Based Fly Ash–Slag Alkali-Activated Mortars Under Aggressive Exposure Conditions

The durability of alkali-activated materials (AAMs) in acidic environments is a key factor governing their suitability as sustainable alternatives to ordinary Portland cement (OPC). This study investigates the acid resistance of fly ash–slag alkali-activated mortars prepared with either seawater-based or distilled water-based activator solutions, thereby addressing the feasibility of substituting potable water in activator preparation. Eleven binder blends were tested, ranging from 100% fly ash (F100G0) to 100% ground granulated blast furnace slag (GGBS, F0G100) in 10% replacement increments, each prepared with both distilled-water (D-series) and seawater-based (M-series) activator solutions. Mortar cubes were exposed to hydrochloric acid (HCl) and sulphuric acid (H2SO4) after curing for 28, 60, 90, and 180 days. Durability was assessed through mass change, compressive strength retention, and ultrasonic pulse velocity (UPV), complemented by X-ray diffraction (XRD) analysis to elucidate mineralogical transformations. Results showed that acid resistance was governed primarily by binder composition: calcium-rich slag (C–A–S–H) systems deteriorated mainly by decalcification under acid exposure, whereas low-calcium fly ash (N–A–S–H) systems degraded more slowly by dealumination. Seawater activation did not significantly compromise acid resistance relative to distilled-water systems, with the two-activator series performing comparably under both HCl and H2SO4. Paired comparisons of the reported blend values showed small, age-dependent differences between the two-activator series: seawater activation modestly delayed strength loss under HCl at intermediate ages, while under H2SO4 it carried a small late-age penalty attributable to reaction of activator-derived chloride compounds with the acid; at most ages, the two series were statistically indistinguishable. X-ray diffraction showed essentially identical phase assemblages in the two series: no crystalline products formed under HCl, where an amorphous silica-rich residue accumulates on fly-ash-rich blends, whereas gypsum was the sole crystalline product under H2SO4, enhanced in seawater-activated fly-ash-rich blends. The findings clarify the role of marine ions in influencing acid degradation and provide guidance for designing sustainable binder systems for chloride- and sulphate-rich service environments. Overall, seawater is shown to be a viable substitute for potable water in activator preparation, retaining acid resistance comparable to distilled-water systems and supporting the development of more sustainable alkali-activated binders.