Mechanical properties and microstructure of alkali activated mortar containing unexpanded clay.

Purpose: In building constructions, due to the decrease of local raw materials and for sustainability purpose, beside the need of light pieces to be used in roofing and false ceiling; an alkali-activated mortar is the new development where pozzolanic material is used instead of cement and activated by an alkaline solution. Therefore, in this research, alkali-activated mortar containing unexpanded clay as a fine aggregate with a dry density of 1652 kg/m3, compressive strength of 3.2 MPa, and thermal conductivity of 0.4 (W/m.K) was produced, also boards were performed in a dimension of 305×152×12 mm as to use them in false ceiling, and reinforced with 0.25 and 0.5% steel fibre to improve their toughness by 370.8% and 1146.1% compared with reference boards, which made them good choice to used them in roofing and secondary ceiling. Design/methodology/approach: For preparation of alkali-activated mortar, low calcium fly ash (FA) was used as a source binder material. In addition, super-plasticizer and unexpanded clay as a fine aggregate (produce from the crushed artificial aggregate) in the ratio of 1:2.75 fly ash/fine aggregate. The paste was prepared by mixing fly ash with an alkali silicate solution, in a solid-to-liquid ratio of 0.4. Alkali silicate activator was prepared by mixing the NaOH and Na2SiO3 solutions at the mass ratios of 2.5. The concentrations of the NaOH was the same molarity of (14M). To improve the mechanical properties of the reference mortar mixture, steel fibre with 0.25 and 0.5% content were added to the mix. The specimens were tested for water absorption, dry density, compressive strength, flexural strengths, flexural toughness, and thermal conductivity, in addition to the Scanning Electron Microscope test (SEM) for all mortar mixes. Alkali-activated mortar boards with (305×152×12 mm) were prepared and tested for flexural strength and toughness. Findings: The results indicated that the modulus of rupture for mortar boards reinforced with 0.25 and 0.5% steel fibre exhibits an increase of (3.68-12.10)%. In comparison, the toughness is increased by about 370.8% and 1146.1%, respectively, as compared with the reference mortar (without fibre) which made them resistance to accident, in addition to use them in roofing due to their thermal insulation. Research limitations/implications: Further research is needed to make a similar board using another sustainable material. We can examine the thermal insulation that we can get from these board, especially in the building in Iraq which the weather faces high temperatures. Practical implications: There is a by-product that we could get from the electricity station in Iraq. We must study how we get rid of it. Originality/value: This paper investigate how to produce a new light board using artificial aggregate made from unexpanded clay, which has many benefits in building insulation roofing. [ABSTRACT FROM AUTHOR]