Influence of activator ratios and concentration on the physio-mechanical and microstructural characteristics of the geopolymers derived from sandstone processing waste.

Natural stones have been utilized to meet various needs of human civilization since ancient times. The exploitation of any resource is associated with the production of redundant materials called wastes. Sandstone waste (SW) is one such waste obtained during the industrial processing of sandstones. Due to its siliceous composition, extensive yield, and disorganized dumping, noxious conditions related to land and human health are promoted. However, the lack of comprehensive engineering studies, mineralogical analysis, and design methodologies associated with the utilization of sandstone processing wastes restricted their applicability only to fillers or partial substitutes with pozzolans and traditional cement in meager volumes. In the past, limited efforts have been made to utilize SW as a construction entity, particularly for binding purposes. Thus, to enhance the scope of its utilization, a comprehensive investigation has been performed in this research to transform sandstone waste into a novel construction material by geopolymerization. Mix design tailoring and laboratory tests were implemented to understand the effects of sodium hydroxide concentration and sodium silicate to sodium hydroxide ratio on the dissolution and physio-mechanical characteristics of SW-based geopolymers. The activator-to-binder ratio was restricted to 0.4 to obtain pastes with sufficient workability without hindering the properties of the matrix. Besides, a high temperature-curing regime was selected based on SW's crystallographic and reactivity analysis. Subsequently, a total of 48 samples were prepared and tested at the curing age of 28 days. Detailed characterization of SW and SW-based geopolymer samples was performed using optical, X-ray, and infrared spectroscopies aided by electron imaging and thermogravimetric techniques. SW-based geopolymer samples showed compressive strengths in the range of 6-12 MPa, ~2 to 3 times higher than those obtained in previous experimentations. Phase analysis and microstructural examinations confirmed SW's participation in geopolymerization. Overall, it could be advocated that geopolymerization is an innovative approach for solving issues related to the disposal and re-utilization of SW, extending its possible application to the fields of cement mixes, wall tiles, mortars, and masonry as per the commendations of ASTM and ACI committee.