Strength and microstructure evaluation of recycled glass-fly ash geopolymer as low-carbon masonry units

• Geopolymerization of recycled glass and flyash to produce a recycled masonry unit.
• Evaluation of unconfined compressive strength with respect to different chemical compositions and curing conditions.
• Microstructure analysis with scanning electron microscope.

The objective of this research was to evaluate the strength development of industrial by-products, namely Recycled Glass (RG) and Fly Ash (FA) in the manufacture of low carbon masonry units. A low carbon concept for manufacturing masonry units using RG-FA geopolymers was explored by applying low curing temperature of 50 °C and a low curing period of just 3–7 days. RG, being rich in silica was used as a filler material. FA, being a silica and alumina rich industrial by-product was used as a precursor in the RG-FA geopolymers. A liquid alkaline activator (L) comprising of a sodium hydroxide-sodium silicate solution was used for the alkali activation of 30% content of FA in the RG-FA blend. Factors found to affect strength development of the RG-FA geopolymers were: (1) the ratio of sodium hydroxide and sodium silicate in the liquid activator, (2) application of a low curing temperature of only 50 °C, (3) short curing periods of just 7 days and (4) the L/FA ratios. A geopolymer composed of a 70% Na2SiO3:30% NaOH ratio with a L/FA ratio of 0.625 was found to be the most efficient combination to provide the required unconfined compression strengths for manufacturing masonry. The usage of RG-FA geopolymers as low carbon masonry units was found to be viable using a low curing period of just 7 days and a curing temperature of just 50 °C. The RG-FA geopolymers had sufficient compressive strength be used as structural masonry units and needed only a low amount of heat treatment to achieve the minimum strength requirement. Optimally, 30% of FA was found to be sufficient for geopolymerization to occur for this novel low carbon RG-FA masonry units. Furthermore, the core materials needed to produce RG-FA masonry units were industrial by-products, the sustainable usage of which would contribute significantly to efficient waste management, through the production of aesthetically pleasing masonry units.