Alkali-activation is a technically sound pathway to valorize industry wastes and by-products, and there has been a burgeoning interest in evaluating the potential of waste streams and/or by-products from different industries as precursors for alkali-activated materials production. In the context of sustainable construction materials, as well as other industrial systems, the use of such non-conventional precursors addresses the challenges associated with the global availability and management of such resource streams. This includes the availability of alternative valorisation routes, the life cycle implications of using waste streams, and the pragmatic issues around incorporating a wide range of precursor materials for future proof this technology. In this chapter an overview of studies utilizing alternative precursors for producing alkali-activated cements is presented, analyzing the characteristics of each resource, and identifying the links between mix design formulations and the performance of the alkali-activated materials produced with them. This in order to elucidate the existing knowledge gaps to facilitate the widespread uptake of such resources as key precursors for producing this type of cements.

The utilization of locally available concrete waste for producing recycled concrete aggregates is recognized as one of the most sustainable ways of satisfying the growing demand for concrete production. However, the quality of concrete waste depends on its origin and it may significantly differ from one concrete structure to another. Knowing the chemical composition of the parent concrete is crucial for determining or verifying the origin of the raw materials. For this reason, pre-demolition concrete waste streams need to be characterized and classified. Therefore, a new non-destructive method for determining the cement and aggregate type in hardened concrete using handheld X-ray fluorescence (hXRF) analyser is presented in this paper. The method was tested on different raw powders and on concretes containing different types of cements including CEM I 42.5 N (Portland cement), CEM II/B-V 42.5 N (Portland-fly ash cement), CEM III/B 42.5 N (GGBFS cement). Combined desktop XRF and Energy-dispersive X-ray Spectroscopy (EDS) measurements were used for the purpose of validation. The results revealed that the curing of concrete affects the results: a dried concrete surface condition was optimal for measurements since it limits the impact of the concrete surface moisture and efflorescence on characteristic element oxides, such as CaO. The effective measurement duration was 30 s. A CEM III/B 42.5 N (GGBFS)-based concrete surface was distinguished from other concretes using Al2O3, MgO and Fe2O3 as characteristic oxides. The inner layers of concrete were rich in SiO2, the oxide characteristic for the aggregate composition tested in this study. This shows that hXRF is suitable for use in concrete, provided that the concrete surface is dried and the characteristic elements are defined to ensure a distinction between different cement and aggregate types. Direct adoption of such characterization, however, requires field testing across a wide range of concrete compositions and in situ conditions.

This paper presents the measurement and analysis of energy consumption of a laboratory jaw crusher during concrete recycling. A method was developed to estimate the power requirements of a lab-scale jaw crusher. The impact of material properties on the crusher performance is studied. Eight concrete strength classes (C20/25–C80/95) were considered in the approach. Concrete specimens were cured for 28 days; at which time, concrete properties were obtained through tests such as bulk density, compressive strength, tensile strength, rebound number and ultrasonic pulse velocity. The impact of different aperture size (5 mm and 25 mm) on the energy consumption was also studied. From the experimental results, it is demonstrated that there is a strong dependance of energy consumption on the compressive strength of concrete. Energy of crushing for specimens with a 90 MPa compressive strength was four times higher than the energy needed to crush specimens with a 28 MPa compressive strength. Furthermore, the crushing requires three times more energy when the smaller aperture size is used to process concrete specimens. The results of this study can form a basis for a future large-scale field analysis and a detailed determination of the energy and economic efficiency of concrete recycling.

Demand for high quality recycled concrete aggregates (RCA) to offset the use of primary materials is significantly rising due to circular economy goals and high-value reuse of concrete. The quality of RCA significantly affects their availability for new concrete production due to the variability of parent concrete streams. The optimization of recycling procedures is under development to improve the quality of RCA, however, the costs and energy efficiency of such processes are of practical concern. With this in mind, this paper presents a new framework for reducing the variability of RCA quality by identifying concrete members before their demolition. The goal of identifying demolished concrete members from a structure is to provide groups of concrete members with similar mechanical and chemical properties through a systematic classification of the structural members. The quality assessment of concrete structures and their mechanical and chemical (composition, contamination) properties prior to demolition is generally recognized as challenging due to the absence of guidelines and the lack of easy-to-use in situ characterization techniques. This paper proposes experimental approaches that can non-destructively determine the properties of concrete structures, with a major emphasis on the measurement of the chemical composition of concrete before demolition. Characteristic quality indicators to classify concrete members are first proposed and can be instrumental in setting up future studies. A new method is proposed for in situ chemical composition testing of existing concrete structures; assuming that no records about the parent concrete are available. Next, the challenging parameters for in situ, non-destructive measurements are outlined. The practical application of the proposed method and its uptake in industry can potentially unlock a huge potential for optimized material recovery and contribute greatly to a fully circular construction industry.

The current understanding of the carbonation of alkali-activated concretes is hampered inter alia by the wide range of binder chemistries used. To overcome some of the limitations of individual studies and to identify general correlations between their mix design parameters and carbonation resistance, the RILEM TC 281-CCC working group 6 compiled carbonation data for alkali-activated concretes and mortars from the literature. For comparison purposes, data for blended Portland cement-based concretes with a high percentage of SCMs (≥ 66% of the binder) were also included in the database. A preliminary analysis of the database indicates that w/CaO ratio and w/b ratio exert an influence on the carbonation resistance of alkali-activated concretes but, contrary to what has been reported for concretes based on (blended) Portland cements, these are not good indicators of their carbonation resistance when considered individually. A better indicator of the carbonation resistance of alkali-activated concretes under conditions approximating natural carbonation appears to be their w/(CaO + Na₂O + K₂O) ratio. Furthermore, the analysis points to significant shortcomings of tests at elevated CO₂ concentrations for low-Ca alkali-activated concretes, indicating that even at a concentration of 1% CO₂, the outcomes may lead to inaccurate predictions of the carbonation coefficient under natural exposure conditions.

The current ability to predict the carbonation resistance of alkali-activated materials (AAMs) is incomplete, partly because of widely varying AAM chemistries and variable testing conditions. To identify general correlations between mix design parameters and the carbonation rate of AAMs, RILEM TC 281-CCC Working Group 6 compiled and analysed carbonation data for alkali-activated concretes and mortars from the literature. For comparison purposes, data for blended Portland cement-based concretes with a high percentage of SCMs (≥66% of the binder) were also included in the database. The results show that the water/CaO ratio is not a reliable indicator of the carbonation rate of AAMs. A better indicator of the carbonation rate of AAMs under conditions approximating natural carbonation is their water/(CaO + MgO_eq + Na₂O_eq + K₂O_eq) ratio, where the index ‘eq’ indicates an equivalent amount based on molar masses. This finding can be explained by the CO₂ binding capacity of alkaline-earth and alkali metal ions; the obtained correlation also indicates an influence of the space-filling capability of the binding phases of AAMs, as for conventional cements. However, this ratio can serve only as an approximate indicator of carbonation resistance, as other parameters also affect the carbonation resistance of alkali-activated concretes. In addition, the analysis of the dataset revealed peculiarities of accelerated tests using elevated CO₂ concentrations for low-Ca AAMs, indicating that even at the relatively modest concentration of 1% CO₂, accelerated testing may lead to inaccurate predictions of their carbonation resistance under natural exposure conditions.

The current understanding of the carbonation and the prediction of the carbonation rate of alkali-activated concretes is complicated inter alia by the wide range of binder chemistries used and testing conditions adopted. To overcome some of the limitations of individual studies and to identify general correlations between mix design parameters and carbonation resistance, the RILEM TC 281-CCC ‘Carbonation of Concrete with Supplementary Cementitious Materials’ Working Group 6 compiled and analysed carbonation data for alkali-activated concretes and mortars from the literature. For comparison purposes, data for blended Portland cement-based concretes with a high percentage of SCMs (≥ 66% of the binder) were also included in the database. The analysis indicates that water/CaO ratio and water/binder ratio exert an influence on the carbonation resistance of alkali-activated concretes; however, these parameters are not good indicators of the carbonation resistance when considered individually. A better indicator of the carbonation resistance of alkali-activated concretes under conditions approximating natural carbonation appears to be their water/(CaO + MgO_eq + Na₂O_eq + K₂O_eq) ratio, where the subscript ‘eq’ indicates an equivalent amount based on molar masses. Nevertheless, this ratio can serve as approximate indicator at best, as other parameters also affect the carbonation resistance of alkali-activated concretes. In addition, the analysis of the database points to peculiarities of accelerated tests using elevated CO₂ concentrations for low-Ca alkali-activated concretes, indicating that even at the relatively modest concentration of 1% CO₂, accelerated testing may lead to inaccurate predictions of the carbonation resistance under natural exposure conditions.

Naast cementvervanging door milieuvriendelijkere cementsoorten is er in een circulair betonontwerp ook een dringende behoefte om zand te vervangen door de fijne fractie die vrijkomt bij de productie van betongranulaat (fRCA). Wat weerhoudt de sector vooralsnog deze stap te zetten?

Momenteel wordt gerecycled beton meestal toegepast als wegfundering en daarmee 'gedowncycled'. Dat komt onder meer doordat er geen informatie beschikbaar is over de kwaliteit van het gesloopte beton. Hoogwaardig hergebruik van gerecyclede toeslagmaterialen in nieuwe betonconstructies vereist een strengere kwaliteitscontrole. Aan de TU Delft wordt nu in samenwerking met Rijkswaterstaat een methode ontwikkeld – een niet-destructieve betonidentificatietechniek gebaseerd op chemische en ultrasone analyse – om ‘gezond’ beton vóór het slopen te karakteriseren en te scheiden van ‘aangetast’ beton. Met die methode kan beton ook worden voorgesorteerd op sterkteklasse en kwaliteit zodat er meer garantie kan worden gegeven voor de kwaliteit van het nieuwe beton.

This paper discusses the state-of-the-art of the fine recycled concrete aggregates (fRCA), focusing on their physical and chemical properties, engineering properties and durability of concretes with fRCA. Based on the systematic review of the published literature, it is impossible to deduce without any further research the guidelines and tools to introduce the widespread application of the fRCA in new concrete whilst keeping the cement contents at least the same or preferably lower. Namely, what is still missing is knowledge on key physico-chemical properties and their relation to the quality of the concrete mix and the concrete performance. This paper sets the foundations for better understanding the quality of fRCA obtained either from parent concrete specifically produced in the laboratory, with controlled crushing and sieving of the recycled aggregates or from field structures. By comparing properties of fRCA with properties of fine natural aggregates, the key limiting properties of fRCA are identified as the high water absorption of fRCA, moisture state of fRCA, agglomeration of particles and adhered mortar. As such, continuous quality of fRCA is hard to be obtained, even though they may be more continuous in terms of chemistry. Advanced characterization techniques and concrete technology tools are needed to account for limiting properties of fRCA in concrete mix design.

In the Netherlands, beside cement replacement with more green cement types, there is also an urgent need for alternative materials for natural sand in new concrete in order to make it circular. Furthermore, the recyclers have raised questions regarding upscaling and the potential of fine recycled concrete aggregates (fRCA) in structural concrete elements since the availability of recycled construction rubble is increasing. The variations in their chemical and physical properties and lack of standards for their quality evaluation is the main reason for not yet using fRCA in new concrete. In this paper, an in-depth characterization of different fRCA is performed in order to define their chemical properties. The properties can be eventually related to concrete mix design and performance (next step), so that fRCA can be classified as a material that can be used in more advanced applications. This is achieved with a multi-level chemical characterization of individual and total fractions (0-0.25 mm, 0.25-4 mm and 0-4 mm) for finding type and content of the original sand and cement phases and potential contamination of selected fractions. The tests include quantification of element composition with X-ray fluorescence (XRF), qualitative and quantitative phase analysis with X-ray diffraction (XRD) and Rietveld method. In addition, cement paste content, chlorides and sulfates of each type of fRCA was measured in order to evaluate contamination of studied material. It was shown that fRCA from different origins have similar chemical and mineralogical composition and contain comparative chloride content. The chemical composition testing can provide a first line control regarding composition and potential contamination of fRCA. After that, it can be decided which additional tests are necessary to be done in order to evaluate the suitability of fRCA for replacement of primary natural fine aggregates in new concrete.

Fine recycled concrete aggregates (fRCA, 0–4 mm) are produced from demolished concrete structures and consist of natural aggregates and old cement mortar. The presence of old cement mortar has detrimental effect on the fresh properties and strength of new concrete. This study aims to investigate the working mechanism and effectiveness of different methods for the optimization of mortar mixtures with fRCA. Three streams of fRCA were considered in the approach. As reference material, river sand was used. The river sand was replaced at 0 wt%, 25 wt% and 50 wt% with fRCA. The use of tailor-made superplasticizers (SP's), drying of fRCA, modified content of 0–0.250 mm, modified mixing sequence, increase of cement content were investigated. Once the mortar mixtures were optimized, the reaction kinetics was investigated with isothermal calorimetry. SP was applied to prevent use of additional water and to maintain mix consistency. When the river sand was replaced at 25 wt% with fRCA, no extra cement was needed. The air content of mortars with fRCA was up to 18 %, due to some unforeseen effects. The results indicated that using as received, agglomerated and unwashed fRCA may have a negative effect on the working mechanism of SP leading to high air content in the fresh mortars. Using dried fRCA has substantially decreased air content in mortars. In addition to drying of fRCA, change of mixing sequence has equal or even superior importance to reduction of air content. As a result, the compressive strength was comparable to reference mix with river sand at 25 wt% replacement level, however, the strength of mortars with 50 wt% fRCA was reduced despite that the cement paste content was increased. The use of fRCA did not affect the kinetics and degree of cement hydration in mortars with 25 wt% fRCA. The positive side of this is that the fRCA can be considered as non-reactive.

Understanding the role of curing conditions on the microstructure and phase chemistry of alkali-activated materials (AAMs) is essential for the evaluation of the long-term performance as well as the optimization of the processing methods for achieving more durable AAMs-based concretes. However, this information cannot be obtained with the common material characterization techniques as they often deliver limited information on the chemical domains and proportions of reaction products. This paper presents the use of PhAse Recognition and Characterization (PARC) software to overcome this obstacle for the first time. A single precursor (ground granulated blast-furnace slag (GBFS)) and a binary precursor (50% GBFS–50% fly ash) alkali-activated paste are investigated. The pastes are prepared and then cured in sealed and unsealed conditions for up to one year. The development of the microstructure and phase chemistry are investigated with PARC, and the obtained results are compared with independent bulk analytical techniques X-ray Powder Fluorescence and X-ray Powder Diffraction. PARC allowed the determination of the type of reaction products and GBFS and FA’s spatial distribution and degree of reaction at different curing ages and conditions. The results showed that the pastes react at different rates with the dominant reaction products of Mg-rich gel around GBFS particles, i.e., Ca-Mg-Na-Al-Si, and with Ca-Na-Al-Si gel, in the bulk paste. The microstructure evolution was significantly affected in the unsealed curing conditions due to the Na⁺ loss. The effect of the curing conditions was more pronounced in the binary system.

The reduction of pH from ~12.5 to ~9 by carbonation of the pore solution of reinforced cementbased concrete structures results in the reinforcement corrosion. The rate of carbonation is an important input for design of the concrete cover depth and the service life prediction of reinforced concrete structures because the initiation of reinforcement corrosion is usually considered as the end of service life of concrete infrastructure. The information from the field carbonation of alkali activated concrete is in most cases limited and related to exposure shorter than 40 years. In this paper, a comparative study regarding accelerated and natural carbonation of alkali-activated concretes and cement-based concretes has been carried out. The pH and carbonation depths are periodically measured. The results show that, despite the low porosity of alkali-activated concrete with 50 wt. % slag, these concretes must have an appropriate curing in order to be used in exposure classes where carbonation is an issue, due to their lower carbonation resistance compared to cement-based concrete. Regardless the exposure conditions, the pH of carbonated alkali-activated concrete was maintained above 9. Finally, recommendations for alkali activated concrete applications and their improved carbonation resistance are given.

In circular concrete design, beside cement replacement with more environmentally friendly cement types, there is also an urgent need for sand replacement with fine recycled concrete aggregates (fRCA). The variations in physical and chemical properties of fRCA and lack of standards for their quality evaluation are the main reasons for not yet using fRCA in new concrete. In this study, an in-depth characterization of different Dutch fRCA is performed in order to examine suitability of fRCA as an alternative material for river sand and define indicators for fRCA quality. These indicators eventually can be related to concrete mix design and performance, so that fRCA can be classified as a material that can be used in structural concrete elements. This is achieved with physical, chemical and mineralogical characterization of individual and total fractions (0–0.250 mm, 0.250–4 mm and 0–4 mm). The physical properties such as grading, density, surface area, water absorption and cement paste content of fRCA were tested. The chemical analyses include quantification of element composition with X-ray fluorescence spectrometry (XRF) and carbonate content with thermogravimetry and mass spectrometry (TG-MS). Potential contamination (chlorides and sulfates) and reactivity of selected fractions were evaluated. In addition, qualitative and quantitative phase analyses with X-ray diffraction (XRD) combined with Rietveld refinement method were performed and supported by optical polarizing-and-fluorescence microscopic (PFM) study. Based on combined experimental approaches, characteristic quality indicators were defined for fRCA. These indicators showed that fRCA were uncontaminated and nonreactive. Despite fRCA were from different origins, they had similar chemical and mineralogical composition and contained comparative chloride content. In contrast, the content and surface area of fine fraction (0–0.250 mm) and particle size distribution of fRCA varied with the source. With this it can be assumed that fRCA will have different effect on the properties of the new concrete.

De kwaliteit van betonmortel kan sterk worden verbeterd door ingrepen in vochtgehalte van het fijne betongranulaat en de mengvolgorde van de toeslagmaterialen bij de bereiding van het beton. In een studie van TU Delft, M2I, TNO en Rijkswaterstaat, dat is uitgevoerd door Marija Nedeljković van de TU Delft, zijn interessante bevindingen vastgelegd.

The pore solutions of a series of hardened alkali-activated slag/fly ash pastes were extracted by the steel-die method, and analyzed using ICP-OES analysis technique. According to the saturation index from thermodynamic calculations, the pore solutions of alkali-activated slag pastes kept oversaturated with respect to solid reaction products with time. In the pore solutions of alkali-activated fly ash pastes, an increase of temperature (from 40 °C to 60 °C) led to decreases of the concentrations of Si, Al, Ca, Na, OH−, K, Fe and Mg, while the soluble silicate in the alkaline activator resulted in increases of the concentrations of these elements. Compared to the alkali-activated slag paste with the same alkaline activator, 50% replacement of slag by fly ash did not result in a substantial change of the pore solution composition. Based on the experimental results, conceptual models were proposed to describe the elemental concentrations in the pore solutions.

The effect of curing conditions (sealed and unsealed) on the pore solution composition and carbonation resistance of different binary alkali-activated fly ash (FA) and ground granulated blast furnace slag (GBFS) pastes is investigated in this study. The studied mixtures were with FA/GBFS ratios of 100:0, 70:30; 50:50, 30:70, 0:100. Ordinary Portland cement (OPC) and Cement III/B (70 wt% of GBFS and 30 wt% OPC) pastes with the same precursor content were also studied to provide a baseline for comparison. Accelerated carbonation conditions (1% (v/v) CO₂, 60% RH for 500 days) were considered for evaluating the carbonation resistance of the pastes. The results show a substantial lower [Na⁺] in the pore solution of the unsealed cured samples compared to the sealed cured samples. It is also found that unsealed curing of the samples leads to a faster carbonation rate. Additionally, it is observed that the carbonation rate decreases with increasing GBFS content independent of the curing conditions. The potential risks with respect to carbonation of the pore solution are also identified and discussed.

This study investigates the effectiveness of metakaolin (MK)in mitigating the autogenous shrinkage of alkali-activated slag (AAS). It is found that the autogenous shrinkage of AAS paste can be reduced by 40% and 50% when replacing 10% and 20% slag with MK, respectively. By providing additional Si and Al, and decreasing the pH of the pore solution, the incorporation of MK retards the formation of aluminium-modified calcium silicate hydrate (CASH)gels, the main reaction products in the studied pastes. The chemical shrinkage and pore refinement are consequently mitigated, resulting in a substantial reduction in the pore pressure. Meanwhile, the elastic modulus of AAS paste is only slightly influenced after MK addition. As a result, the autogenous shrinkage of AAS is significantly mitigated by incorporating MK. In addition, the introduction of MK would extend the setting time, slightly decrease the compressive strength, but greatly increase the flexural strength of AAS.

As the building sector is expanding, a growing interest in technologies that can reduce the CO2 emission from concrete production has led to partial replacement of cement with by-products from various industrial processes. Besides the partial replacement of cement, development of alkali activation technology ensures full replacement of cement in concrete. Although alkali activated materials (AAMs) are one of the most sustainable alternatives to cement-based concrete, structural application of AAMs is still not viable, as their long-term performance is not sufficiently studied. For instance, no recommendations are yet given to the scientific and engineering communities as a general approach for testing carbonation of AAMs. Furthermore, there is a limited number of case studies of long-term performance of AAMs in the past to assist the predictive models of their service life. The long-term performance (carbonation resistance) of AAMs is mainly dependent on the microstructure features of the binder (e.g. phase assemblages and pore structure), which can be modified using different constituents and materials mixture designs. Therefore, the aim of this thesis was the development of a conceptual carbonation mechanism that can be applied to analyse carbonation resistance of any alkali activated concrete mixture. For this reason, the carbonation mechanism was studied at different length scales, from paste to concrete level, while the effects of carbonation on the chemical, physical and mechanical properties were captured. The relationship between carbonation rate, pore solution chemistry and microstructure was investigated. An advanced microstructure characterization of fly ash (FA) and ground granulated blast furnace slag (GGBFS) was performed using PARC software. The combined effect of GGBFS content, curing (sealed/unsealed) and exposure conditions (natural indoor/outdoor and accelerated carbonation) on the carbonation resistance of pastes was considered. Based on the parameter studies (GGBFS content, curing, exposure conditions), recommendations for design of alkali activated concrete for engineering practice are given in view of carbonation resistance.