Developing a sustainable self-compacting geopolymer concrete with 100% geopolymer-coated recycled concrete aggregate replacement

PurposeConcrete, the second most used material in the world, surpassed only by water, relies on a vast amount of cement. The process of cement production emits substantial amounts of carbon dioxide (CO2). Consequently, it is crucial to search for cement alternatives. Geopolymer concrete (GC) uses industrial by-product material instead of traditional cement, which not only reduces CO2 emissions but also enhances concrete durability. On the other hand, the disposal of concrete waste in the landfills represents a significant environmental challenge, emphasising the urgent need for sustainable solutions. This study aimed to investigate waste concrete's best form and rate as the alternative aggregates in self-compacting and ambient-cured GC to preserve natural resources, reduce construction and demolition waste and decrease pertinent CO2 emissions. The binding material employed in this research encompasses fly ash, slag, micro fly ash and anhydrous sodium metasilicate as an alkali activator. It also introduces the best treatment method to improve the recycled concrete aggregate (RCA) quality.Design/methodology/approachA total of25%, 50% and 100% of coarse aggregates are replaced with RCAs to cast self-compacting geopolymer concrete (SCGC) and assess the impact of RCA on the fresh, hardened and water absorption properties of the ambient-cured GC. Geopolymer slurry was used for coating RCAs and the authors examined the effect of one-day and seven-day cured coated RCA. The mechanical properties (compressive strength, splitting tensile strength and modulus of elasticity), rheological properties (slump flow, T500 and J-ring) and total water absorption of RCA-based SCGC were studied. The microstructural and chemical compositions of the concrete mixes were studied by the methods of energy dispersive X-Ray and scanning electron microscopy.FindingsIt is evident from the test observations that 100% replacement of natural aggregate with coated RCA using geopolymer slurry containing fly ash, slag, micro fly ash and anhydrous sodium metasilicate cured for one day before mixing enhances the concrete's quality and complies with the flowability requirements. Assessment is based on the fresh and hardened properties of the SCGC with various RCA contents and coating periods. The fresh properties of the mix with a seven-day curing time for coated RCA did not meet the requirements for self-compacting concrete, while this mix demonstrated better compressive strength (31.61 MPa) and modulus of elasticity (15.39 GPa) compared to 29.36 MPa and 9.8 GPa, respectively, for the mix with one-day cured coated RCA. However, incorporating one-day-cured coated RCA in SCGC demonstrated better splitting tensile strength (2.32 MPa) and water absorption (15.16%).Research limitations/implicationsA potential limitation of this study on SCGC with coated RCAs is the focus on the short-term behaviour of this concrete. This limited time frame may not meet the long-term requirements for ensuring the sustained durability of the structures throughout their service life.Originality/valueThis paper highlights the treatment technique of coating RCA with geopolymer slurry for casting SCGC.