Characterization of mechanically activated fly ash-based lightweight geopolymer composite prepared with ultrahigh expanded perlite content

This study focused on the optimization of the production conditions of an ultrahigh expanded perlite lightweight aggregate-filled fly ash-based geopolymer composite and the determination of its product properties. The geopolymer matrix was synthetized using mechanically activated fly ash and an alkaline solution. In a systematic series of experiments, the effect of expanded perlite (EP) content, the compaction pressure and the compaction time on the mechanical properties of the lightweight composite were investigated. In the case of the optimal production conditions, the composites were characterized in terms of physico-mechanical properties, water absorption and microstructure. The composites produced under optimal conditions had an average uniaxial compressive strength of 246 kPa and density of 534 kg/m3 at 80% by volume EP content, and 264 kPa and 221 kg/m3 at 95% by volume EP content. Both the FT-IR spectroscopy and scanning electron microscopy results proved the formation of main geopolymerization reaction products in the matrix of the composite, as well its reaction with the lightweight aggregate.