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<p>Modern construction increasingly emphasizes sustainability and fire resistance, driving the development of materials capable of maintaining mechanical integrity after exposure to elevated temperatures. Despite the growing interest in electric arc furnace slag and fly ash as sustainable precursors, the mechanisms governing their thermo-mechanical behaviour and residual performance after severe thermal exposure have not been comprehensively established. This study investigates a binary blend of electric arc furnace slag and fly ash in alkali-activated mortar, with particular emphasis on residual strength and microstructural stability after fire exposure. A Taguchi experimental design was adopted, and sixteen mortar mixtures were exposed to elevated temperatures of 500&#xa0;°C and 900&#xa0;°C. The specimens were subsequently evaluated for residual compressive strength, weight loss, surface porosity, and microstructural evolution using X-ray diffraction and scanning electron microscopy. The results showed that mixtures containing only electric arc furnace slag retained significant structural integrity after heating due to the formation of stable crystalline phases and the presence of microporosity that reduced thermal stresses. In contrast, mixtures containing 25% electric arc furnace slag and 75% fly ash, although denser under ambient conditions, experienced severe degradation after heating because of gel incompatibility and moisture-induced cracking. The alkali-activated mortar containing electric arc furnace slag exhibited residual strength retention of approximately 50% at 500&#xa0;°C and 14% at 900&#xa0;°C. The mechanisms governing strength retention were further analysed through phase transformation and microstructural observations obtained from X-ray diffraction and scanning electron microscopy. Overall, the findings demonstrate that electric arc furnace slag-rich alkali-activated materials are promising sustainable and fire-resistant alternatives to ordinary Portland cement, providing valuable insights for structural fire safety applications requiring durable and low-carbon construction materials.</p> Graphical Abstract <p>Experimental workflow and key findings of EFAM subjected to elevated temperatures</p> <p></p>

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Innovative EAF slag-based eco-friendly mortars for fire-resistant infrastructure

  • 期刊论文

  • 发表日期：

    2026年7月18日

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  • Anant Mishra,
  • Pragyan Upadhyay,
  • Diksha,
  • Gaurav Tyagi,
  • Mukund Lahoti

摘要

Modern construction increasingly emphasizes sustainability and fire resistance, driving the development of materials capable of maintaining mechanical integrity after exposure to elevated temperatures. Despite the growing interest in electric arc furnace slag and fly ash as sustainable precursors, the mechanisms governing their thermo-mechanical behaviour and residual performance after severe thermal exposure have not been comprehensively established. This study investigates a binary blend of electric arc furnace slag and fly ash in alkali-activated mortar, with particular emphasis on residual strength and microstructural stability after fire exposure. A Taguchi experimental design was adopted, and sixteen mortar mixtures were exposed to elevated temperatures of 500 °C and 900 °C. The specimens were subsequently evaluated for residual compressive strength, weight loss, surface porosity, and microstructural evolution using X-ray diffraction and scanning electron microscopy. The results showed that mixtures containing only electric arc furnace slag retained significant structural integrity after heating due to the formation of stable crystalline phases and the presence of microporosity that reduced thermal stresses. In contrast, mixtures containing 25% electric arc furnace slag and 75% fly ash, although denser under ambient conditions, experienced severe degradation after heating because of gel incompatibility and moisture-induced cracking. The alkali-activated mortar containing electric arc furnace slag exhibited residual strength retention of approximately 50% at 500 °C and 14% at 900 °C. The mechanisms governing strength retention were further analysed through phase transformation and microstructural observations obtained from X-ray diffraction and scanning electron microscopy. Overall, the findings demonstrate that electric arc furnace slag-rich alkali-activated materials are promising sustainable and fire-resistant alternatives to ordinary Portland cement, providing valuable insights for structural fire safety applications requiring durable and low-carbon construction materials.

Graphical Abstract

Experimental workflow and key findings of EFAM subjected to elevated temperatures