Although alkali-activated materials (AAMs) show great promise as viable substitutes for Ordinary Portland Cement (OPC), they face numerous challenges in achieving widespread market acceptance. These challenges include the intricate chemistry of AAMs, technological and environmental complexities, inconsistency in the availability and quality of raw materials, and the absence of a well-established value chain for AAM production. Furthermore, legislative and regulatory frameworks are often lacking or unfavorable, and economic concerns related to scalability and competitiveness continue to pose barriers. Social acceptance remains limited, often due to unfamiliarity with the material and skepticism about its long-term performance. This chapter presents findings from various international research and development projects focused on advancing AAM technology. It highlights the pivotal role of pilot-scale trials in assessing the feasibility of AAM implementation, identifying technical and logistical challenges, and guiding further innovation. Additionally, the chapter showcases successful case studies and industrial applications of AAMs, positioning them as sustainable, high-performance alternatives to both traditional OPC and ceramic-based construction materials.

Among the various examples of sustainable construction materials explored in scientific literature, alkali-activated materials excel as one of the most mature and reliable solutions for large scale applications. It consists on the combination of an alkaline source in liquid or solid state, and a partially-to-fully amorphous solid precursor. The combination of these components leads to the obtainment of a hardened material which resembles Portland-cement based products. The performance and durability of these alternative binders is highly dependent on their components and production methods, and multiple laboratorial- and industrial-scale examples have shown their capability of outperforming conventional building materials. Practical challenges with variations in chemistry and mineralogy of raw materials, and the global utilization of prescriptive standards for structural building materials, hinder a wider utilization of these binders, and the efforts of the scientific and applied industry communities in overcoming these barriers is detailed throughout this report. This chapter provides an overview of alkali-activated binders, summarizing the main characteristics of their components, their reaction mechanisms, their challenges, and the expected advances of the technology with respect to one-part binders.

The recycling of municipal solid waste incineration (MSWI) bottom ash as a supplementary cementitious material (SCM) has attracted global attention, driven by the increasing availability of this by-product and the demand for sustainable SCMs to lower CO₂ emissions from cement production. Currently, the widespread use of MSWI bottom ash in the cement industry is hindered by the lack of guidelines to regulate material composition, optimize pretreatment processes, and specify mix design requirements. This review compiles and analyzes literature data on mix design, microstructural evolution, fresh properties, mechanical properties, durability, leaching risks, and environmental impacts of MSWI bottom ash-blended cement pastes, mortars, and concretes. The analysis aims to assess the influence of the pretreatment and physicochemical properties of bottom ash¹ on the microstructure and performance of blended cementitious materials.² The Ash Impact Strength Index (AISI) is introduced to quantify the effects of various factors on compressive strength, enabling direct comparison across different studies. Based on the statistical analysis of the 28-day AISI, the key quality requirements for MSWI bottom ash as an SCM are proposed, along with the optimal mix design. This work provides valuable insights and practical guidance to support the integration of bottom ash into the cement industry.

Alkali-activated foams are ceramic-like materials prepared at near-ambient temperature. This study investigates them for point-of-use water disinfection, thus providing an alternative to ceramic filters fired at a high temperature. Alkali-activated foams with different compositions were characterized for the porosity, mechanical strength, shrinkage, and microstructure. The optimized foam, employing metakaolin as the raw material, was coated with a colloidal Ag solution. The disinfection performance and leaching behavior of the foams was followed in a continuous 10 week experiment, where clean water with a weekly pulse of contaminated water was distributed through the foam. The average inactivation of Escherichia coli with the Ag-coated foam was 2.84 log₁₀, which was 1.27 units higher compared to foam without Ag. A quantitative polymerase chain reaction analysis and metagenomic sequencing verified that foams with and without Ag were both capable of reducing the microbial load. Furthermore, the changes induced by the foam with Ag on the microbial community composition, antibiotic resistome, and metal and biocide resistomes were significant. The leached concentrations of Ag, Na, Si, and Al were in accordance with the drinking water guidelines. Finally, a life cycle assessment indicated the possibility of reducing the global warming potential and the total embodied energy in comparison with a conventional ceramic filter.

Two synthesis pathways (one- and two-part) in alkali-activated binders were compared using ground granulated blast furnace slag (GGBFS), mineral wool (MW) activated using dry and liquid alkali activators with similar Na₂O/SiO₂ modulus. The effect of activator type on reaction kinetics, strength development, setting times, and durability shows that one-part synthesis does not only improve early strength, but also provide better durability properties. While the highest compressive strength (56 MPa, 90 days) was achieved for the one-part mix (DM), the reaction products (presence of Mg–Al layered double hydroxide and C–S–H-like phases) observed for both mortar mixes were similar. The DM mortars showed better resistance to sulfate attack than two-part mix (WM) mortars and sets faster. The results highlight the significance of the one-part pathways in the synthesis of alkali-activated materials.