Mechanical Properties and Sulfate Resistance of High Volume Fly Ash Cement Mortars with Air-Cooled Slag as Fine Aggregate and Polypropylene Fibers

The depletion of natural sand and production of the huge amount of cement in the construction industry are serious threats to the environment, which can be reduced by the utilization of by-products as cement replacement material. In this study, cement was replaced with fly ash up to 45% (by weight). In addition, the natural fine aggregate was replaced with air-cooled blast furnace slag aggregate (here referred to as “slag aggregate”) at a level of 50% and 100% (by weight). Polypropylene fiber was also added, at a dosage of 0.25% of binder weight. Mortar specimens were prepared and analyzed using tests for compressive, flexure, and splitting tensile strength, as well as for microhardness, and ultrasonic pulse velocity. In addition, the specimens were exposed to sulfate solution and investigated for changes in length, mass, and compressive strength. Electron microscopy and X-ray diffraction analysis were performed to examine the microstructure and phase changes of mortar specimens exposed to sulfate solution. The results indicate that mortar specimens made with 50% slag aggregate and 0.25 % fiber showed enhanced mechanical properties. The performance of slag aggregate mortars under sulfate attack was improved significantly.