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<p>The construction industry’s environmental impact requires sustainable material innovations, particularly in concrete binders, which are typically energy intensive. The research focuses on the application of silica-rich waste glass powder (WGP), an industrial by-product, to create an environmentally friendly activator powder to develop one-part alkali activated binders (OAABs). In this regard, we developed an energy-efficient approach for synthesizing a powder alkali activator from WGP, aimed at producing a clinker-free binder through a mechano-thermal activation process, thereby reducing the carbon footprint of construction materials. This method of developing activators at a relatively low temperature (100&#xa0;°C) for three different process durations (1&#xa0;h, 2&#xa0;h and 3&#xa0;h) simplifies the manufacturing process by reducing the complexity of multi-constituent systems while enhancing the material’s properties. We evaluated the prepared binders for their fresh properties, compressive strength and microstructural characteristics (SEM, XRD, FT-IR and TGA) apart from sustainability indicators. Out of all, Type 3 activators (100&#xa0;°C for 2&#xa0;h) outperformed other types with a maximum compressive strength of 63.39&#xa0;MPa recorded for M3 mix with a significantly reduced CO<sub>2</sub> emission by 86.7% than Portland cement (PC)-based mix. The results indicate that the clinker-free binders produced from WGP-based activators perform better than conventional binders (PC and AAB made of commercial sodium silicate solution and powder) in terms of enhanced mechanical properties with compact microstructure and reduced environmental issues.</p>

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Innovative approaches to sustainable powder activator production from silica-rich industrial waste for clinker-free one-part binders in green construction materials

  • 期刊论文

  • 发表日期：

    2025年11月11日

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  • Anoop Kallamalayil Nassar,
  • Ramanathan Palanimurugan,
  • Parthiban Kathirvel,
  • G. Murali,
  • Saurav Dixit

摘要

The construction industry’s environmental impact requires sustainable material innovations, particularly in concrete binders, which are typically energy intensive. The research focuses on the application of silica-rich waste glass powder (WGP), an industrial by-product, to create an environmentally friendly activator powder to develop one-part alkali activated binders (OAABs). In this regard, we developed an energy-efficient approach for synthesizing a powder alkali activator from WGP, aimed at producing a clinker-free binder through a mechano-thermal activation process, thereby reducing the carbon footprint of construction materials. This method of developing activators at a relatively low temperature (100 °C) for three different process durations (1 h, 2 h and 3 h) simplifies the manufacturing process by reducing the complexity of multi-constituent systems while enhancing the material’s properties. We evaluated the prepared binders for their fresh properties, compressive strength and microstructural characteristics (SEM, XRD, FT-IR and TGA) apart from sustainability indicators. Out of all, Type 3 activators (100 °C for 2 h) outperformed other types with a maximum compressive strength of 63.39 MPa recorded for M3 mix with a significantly reduced CO2 emission by 86.7% than Portland cement (PC)-based mix. The results indicate that the clinker-free binders produced from WGP-based activators perform better than conventional binders (PC and AAB made of commercial sodium silicate solution and powder) in terms of enhanced mechanical properties with compact microstructure and reduced environmental issues.