Influence of precursor materials on the fresh state and thermo-chemo-mechanical properties of sodium-based geopolymers

Aluminosilicates are the base precursors that combined with alkali solutions manufacture geopolymers. A wide variability of aluminosilicate precursors can be found in the market worldwide, which may be an issue when proposing single designs. The goal of this study is to compare the use of different precursors in the hardening mechanisms of geopolymers. For this, two types of metakaolin (a low (MK_LR) and a high-reactive (MK_HR) one), and partial replacements made with fly-ash (FA) and blast furnace slag (BFS) are used in SiO₂/Al₂O₃ = 4.00, Na₂O/SiO₂ = 0.25, and H₂O/Na₂O = 11.00 fixed design ratios. Fresh state (viscosity and squeeze flow), transient state (Vicat needle and sonic strength), and hardening measurements (compression tests under room and high temperature conditions), were used, supported by chemical analysis (calorimetry and SAM/HCl extraction) and materials characterization (particle analysis, density, BET and XRD). In general, the reactivity, chemical composition, and morphology of each precursor, as well as solid/liquid portions of each mix were major factors influencing the hardening process. The use of MK_LR achieved shorter setting times and enhanced viscosities due to its particles larger surface area, solid/liquid ratios, and unreactive portions, reaching the highest values of strength and diminished thermomechanical performance. Partial substitutions made with FA and BFS increased the amorphous part of the binder, increasing also its flowability, setting time, and its stability to thermal exposure. The geopolymer made with MK_HR presented the lowest viscosity and longer setting time due to its almost constant dissolution rate, attributed to its enhanced reactivity from highly amorphous parts and diminished solid-to-liquid ratio mixture. Therefore, the use of varied aluminosilicates significantly modifies the materials properties, leading to different potential applications that should be considered when designing geopolymers.