Phosphate-based geopolymer: Influence of municipal solid waste fly ash introduction on structure and compressive strength

Materials resulting from incorporation of solid waste incineration fly ash into phosphate-based geopolymers, to partially replace metakaolin (up to 50% wt), were studied. X-ray diffraction, scanning electron microscopy, solid-state nuclear magnetic resonance spectroscopy and infrared spectroscopy were adopted to describe the mineralogical changes and the structural modifications of the geopolymer networks which impacted on the mechanical performance (compressive strength) of the materials. The results indicated that fly ash displays a different reactivity compared with metakaolin, behaving preferentially as a source of alkali that compete with the aluminosilicate metakaolin fraction by precipitating crystalline and amorphous phosphates. At 10 wt% of metakaolin substitution with fly ash, the extent and reticulation of the amorphous geopolymer matrix is preserved, and the mechanical properties are retained. At higher waste content (30–50% wt), the fast kinetics of the acid-base reactions involving the fly ash reactive phases prevail over the metakaolin dealumination, and the nature of the material shifts to an alkali-phosphate cement/phosphate-geopolymer composite. This behaviour, together with the development of porosity and presence of low-strength phases in the ash, led to a decline in the mechanical performance with increasing amount of substitution. All in all, this work provides fundamental information in the direction of a sustainable employment of phosphate-based geopolymers, which is limited by the relatively high cost of both metakaolin and phosphoric acid. Moreover, it indicates a recycling opportunity for this type of fly ash.