Development of a low-cost cement free polymer concrete using industrial by-products and dune sand

Alkali-activated polymer concrete (APC) can potentially reduce CO₂ emissions associated to concrete production by 84%. The binder in APC herein was synthesized using a combined sodium silicate-sodium hydroxide solution (i.e., alkali activator), alumino-silicate rich precursor (fly ash) and slag. Light weight expanded clay and desert dune sand were used as aggregates. An overview of an experimental program was presented, which involved evaluation of fresh and mechanical properties of the produced APC and counterpart mortar (APM). Variables investigated were the fly ash to slag ratio and curing conditions. The curing regimes adopted herein included 24 hours of curing at ambient conditions, 30°C, and 60°C. The experimental program was undertaken in two stages, of these the first stage involved physical and chemical testing of constituent materials and the second stage involved testing or produced APM/APC. Reported were the setting times, workability, compression strength, strength development, flexural strength, tensile splitting strength, and plastic shrinkage strains. Relationship between strength results were investigated and effectiveness of codified predictive equations was evaluated.