Mechanical and durability properties of sustainable alkali-activated mortars with ceramic insulator waste and andesite powder as partial substitutes for GBFS

This study explores the use of andesite powder (AP) and ceramic waste powder (CWP), derived from discarded electrical insulators, as supplementary precursors to ground granulated blast furnace slag (GBFS) in alkali-activated self-compacting mortars. The originality of the work lies in the combined utilization of these regionally sourced aluminosilicate wastes in binary and ternary binder systems, aiming to reduce GBFS dependency while ensuring adequate mechanical and durability performance. AP and CWP were used to replace GBFS at up to 50%, and the mixtures were evaluated for flowability, mechanical strength, density, porosity, water absorption, and capillary sorptivity. Durability was assessed through freeze–thaw cycling and high temperature exposure, and microstructural characteristics were examined using scanning electron microscope analysis. Results showed that while partial substitution with AP or CWP reduced compressive strength compared to the GBFS control, the incorporation of CWP in ternary systems partially compensated for the strength losses associated with AP. High temperature resistance improved markedly with increased CWP content; at 900°C, the 50% CWP mixture retained 44% of its original compressive strength, in contrast to 8% for the control. Although all mixtures containing waste exhibited reduced freeze–thaw resistance, mortars containing CWP exhibited superior performance compared to those with only AP. These findings highlight the potential of CWP, particularly in ternary systems, for developing sustainable alkali-activated mortars.