In this research, the properties and cementitious performance of thermally activated cement pastes (referred to as DCPs) are investigated. Hydrated pastes prepared from Portland cement and slag blended cement were subjected to different thermal treatments: 350 °C for 2 h, 550 °C for 2 h, 550 °C for 24 h and 750 °C for 2 h. The properties and the reactivity as SCM of the DCPs were characterised as well as their effect on the mechanical performance and hydration of new blended cements incorporating the DCPs as supplementary cementitious materials (SCMs). It was observed that the temperature and duration of the thermal treatment increased the grindability and BET specific surface area of the DCP, as well as the formation of C₂S phases and the reactivity as SCM. In contrast, the mechanical strength results for the blended cements indicated that thermal treatment at 350 °C for 2 h provided better performance. The hydration study results showed that highly reactive DCP interfered with the early hydration of the main clinker phases in Portland cement, leading to early setting and slow strength gain. The effect on blended cement hydration was most marked for binary Portland cement–DCP blends. In contrast, in the case of ternary slag cement–DCP blends the use of reactive DCP as SCM enabled to significantly increase early age strength.

Copper slag (CS) remains a challenging industrial by-product with a relatively small utilization fraction. The present study investigated the development of one-part alkali-activated cements based on CS, ground granulated blast furnace slag (GGBS) and a mixture of the two as a precursor. We investigated 5 to 15 wt% solid sodium metasilicate (Na₂SiO₃) and disilicate (Na₂Si₂O₅) as alkaline reagents. Isothermal calorimetry showed that the reactivity of the system was higher for the metasilicate based samples, with early reaction and higher cumulative heat released. Metasilicate based samples also presented a more densified microstructure, lower porosity and higher strength. Better performances were observed with 10 wt% metasilicate/disilicate with respect to the 5 and 15 wt%. The 28-day compressive strength and elastic modulus of 10 wt% metasilicate samples reached 75 MPa and 25 GPa, respectively, and, for paste samples, ranged from 100 wt% GGBS to 50/50 wt% CS/GGBS. The microstructure and calorimetry of the pastes showed that GGBS actively participated in the binding process, whereas CS played a smaller role and acted as a filler and catalyst. The substitution of commercial GGBS by CS up to 50 wt% did not affect the overall performance, thus, bringing CS forward as an economically interesting precursor.

Copper slag is an industrial residue with a large unutilized fraction. This study presents the development of alkali-activated composites from a copper slag named Koranel^®. The effects of metakaolinite, ordinary Portland cement (OPC) and surfactants were investigated. The reactivity of Koranel with potassium silicate solutions with molar ratio R = SiO₂/K₂O varying from 1 to 2.75, with 0.25 intervals, was investigated using isothermal calorimetry. The reactivity was relatively low at 20 °C; the reaction started after a few hours with a low silica modulus, to several weeks with the highest silica modulus. The substitution of Koranel by OPC (5 wt.%) or by metakaolinite (10–20 wt.%), both led to higher reaction heat and rate; meanwhile, the addition of 2 wt.% polyethylene glycol/2-methyl 2,4 pentanediol delayed the reaction time in the system containing metakaolinite. Raising the curing temperature from 20 °C to 80 °C shortened the setting time of the low reactive systems, from several days to almost instantaneous, opening perspectives for their application in the production of prepreg composite materials. The use of carbon fabric as reinforcement in the alkali-activated matrix led to composite materials with flexural strength reaching 88 MPa and elastic modulus of about 19 GPa—interesting for engineering applications such as high-strength lightweight panels.