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Construction and Building Materials 136 (2017) 298–306

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Construction and Building Materials


journal homepage: www.elsevier.com/locate/conbuildmat

Synthesis and properties of alkali activated borosilicate inorganic


polymers based on waste glass
Taha H. Abood Al Saadi a,b, Alina Ioana Badanoiu a,⇑, Adrian Ionut Nicoara a, Stefania Stoleriu a,
Georgeta Voicu a
a
University Politehnica of Bucharest, Faculty of Applied Chemistry and Materials Science, Dept. Science and Engineering of Oxide Materials and Nanomaterials, Bucharest, Romania
b
Middle Technical University/Technical Engineering College-Baghdad, Iraq

h i g h l i g h t s g r a p h i c a l a b s t r a c t

 Inorganic polymers from alkali


activation of waste glass with NaOH
+ borax solution.
 These materials have intumescent
behavior.
 Fly ash addition improves their
stability in humid environment.

a r t i c l e i n f o a b s t r a c t

Article history: Alkali activated borosilicate inorganic polymers (AABSIP) can be obtained by the alkali activation of waste
Received 24 March 2016 glass powder with a NaOH solution in which anhydrous borax was previously dissolved. AABSIPs have
Received in revised form 22 December 2016 the ability to swell during the thermal treatment increasing their volume and apparent porosity. The
Accepted 8 January 2017
temperature at which these materials swell is smaller as compared with the one assessed for the inor-
Available online 21 January 2017
ganic polymers obtained by the alkaline activation with NaOH solution of waste glass powder. The partial
substitution of glass powder with fly ash (10%) do not substantially modifies the AABSIP behavior at high
Keywords:
temperatures. The presence of fly ash improves the stability in humid environment (moisture) of AABSIP.
Alkali activated inorganic polymer
Geopolymer
The intumescent behavior (i.e. swelling as a result of heat/fire exposure) is less affected for the AABSIP
Waste glass paste with fly ash when it’s curing take place in humid medium (moisture) as compared to the compo-
Borax sition without fly ash.
Foam Ó 2017 Elsevier Ltd. All rights reserved.
Intumescent material

1. Introduction variety of natural minerals or industrial wastes) and an alkaline


activator solution (caustic alkalis or alkaline salts). Among the
Alkali activated inorganic polymers or geopolymers are materi- numerous wastes that can be used as solid or/and liquid
als that can be produced from an aluminosilicate source (a wide component for the synthesis of this type of materials [1–5], our
research group selected two i.e. waste glass (cullet) and red mud
slurry (waste resulted in bauxite processing industry) [6–9]. The
⇑ Corresponding author. results obtained so far pointed out the possibility to re-use
E-mail address: alina.badanoiu@upb.ro (A.I. Badanoiu).

http://dx.doi.org/10.1016/j.conbuildmat.2017.01.026
0950-0618/Ó 2017 Elsevier Ltd. All rights reserved.
Taha H. Abood Al Saadi et al. / Construction and Building Materials 136 (2017) 298–306 299

silica-soda-lime waste glass powder or mixtures of waste glass and 56 MPa. According to these authors, the microstructure of AABSIP
red mud in order to produce binding materials (geopolymers) by is similar to the one of geopolymers i.e. a porous, glassy matrix
alkaline activation with NaOH solution and thermal treatment at with some non dissolved silica particles and borax crystals [17].
60 °C [6–8]. One interesting property of these materials was their The above mentioned studies focused on different aspects
ability to swell, with important increase of volume and porosity, regarding the properties and application of geopolymers/alkali
during thermal treatment [7]; therefore, is possible to produce activated inorganic polymers with boron content i.e. controlled
foamed geopolymers by the alkali activation of finely ground setting time [14], high mechanical strength [15,16] and neutron
soda-lime glasses (with/without red mud addition) and thermal shielding application [17]; therefore, to the best of our knowledge,
treatment at 600–800 °C, without using any other foaming agents we present for the first time in this paper results regarding the
[7,10]. thermal behavior of AABSIP based on waste glass.
This ability to swell during the thermal treatment is specific for Previous results obtained on geopolymers based on waste glass
intumescent materials; therefore, other possible application for powder showed a low hydrolytic stability of these materials due to
these materials, obtained by the alkaline activation of waste glass, the presence as main reaction products of soluble sodium
can be as intumescent materials for passive fire protection. The silicate (aluminate) hydrates [6,8,9]; therefore, in this study we
currently available intumescent materials can be used for door used also fly ash in some formulation, in the attempt to improve
seals, penetration or linear gap sealants, etc. and have, in most the hydrolytic stability of AABSIP materials.
cases, lower values for the initiation temperatures (140–200 °C)
[11]. Therefore, considering the fluxing ability of boron compounds
[12,13] we assess in this study the possibility to obtain alkali acti- 2. Materials and methods
vated inorganic polymers (geopolymers) based on waste glass
powder with borax addition. 2.1. Materials
The use of boron compounds in the reagent mixture specific for
geopolymers (alkali activated inorganic polymers) synthesis was Mixed waste glass powder (MG) was obtained by the grinding
also reported in the following four studies [14–17]. of cullet with various colors, from a glass recycling facility.
Nicholson and Fletcher [14] reported the synthesis of a novel The main compounds of this soda-lime waste glass powder are:
geopolymer compositions with structurally incorporated boron; silica (70.45 wt%), alkalis (Na2Oeq = Na2O + 0.658K2O) 13.25 wt%,
these materials can be obtained from a reagent mixture compris- calcium oxide (9.75 wt%), aluminium oxide (2.24 wt%) and iron
ing/including a metal (group I – alkali) silicate, an aluminosilicate oxide (1.65 wt%). The Blaine specific surface area of MG powder
and a boron containing compound. In this new type of geopolymer was 3265 cm2/g.
the boron represents an integral part of the structure and it may Fly ash, a by-product resulted in the combustion of pulverized
substitute the tetrahedral aluminium or silicon. According to the coal in a thermal power plant, was used as solid component for
authors these materials have as main advantage a longer setting inorganic polymer preparation. The Blaine specific surface area of
time with respect to aluminosilicate geopolymers based on fly this material was of 4594 cm2/g. The oxide and mineralogical com-
ashes with high calcium content (class C fly ash). positions of fly ash are presented in Table 1.
Nazari et al. [15,16] reported also the synthesis of boroalumi- The anhydrous borax was obtained by the thermal treatment of
nosilicate geopolymers by the alkaline activation of fly ash (class borax (Na2B4O710H2O) at 150 °C for 30 min followed by a second
F) with a mixture of NaOH solution and anhydrous borax. The thermal treatment at 300 °C for 15 h [17].
compressive strengths of these materials reached 64 MPa, after The formulations of AABSIP specimens are based on a recipe
90 days of hardening [15]. According to these authors, the pres- proposed by Williams & Van Riessen [17], and are presented in
ence of B–O bonds in the boroaluminosilicate structure could Table 2.
explain the high values of the compressive strengths; moreover, MGB was prepared by mixing the solid component (MG glass
the microstructure of boroaluminosilicate geopolymers is com- powder) with the liquid component i.e. a solution obtained in
pletely different from the one of traditional aluminosilicate two steps: i) dissolution of NaOH pellets in water, and ii) addition
geopolymers [15,16]. of anhydrous borax (Na2B4O7).
Williams and van Riessen [17] obtained a new class of materials After the borax addition the solution was fast converted into a
with boron content by the alkali activation of silica fume with a gel like phase. This solution was mixed with glass powder (MG)
mixture of NaOH solution and anhydrous borax; these materials, or with mixtures of glass powder and fly ash (MGBF). The worka-
called alkali activated borosilicate inorganic polymers (AABSIP), bility of the paste was initially good but rapidly decreased and
have compressive strengths comprised between 45 MPa and the material stiffened in few minutes. In order to obtain more

Table 1
Oxide and mineralogical composition of fly ash (F).

Oxide composition (wt.%) LOI SiO2 Al2O3 Fe2O3 CaO MgO SO3 SiO2/Al2O3
6.05 40.41 19.02 13.82 12.5 2.59 5.43 2.21
Mineralogical composition Iron calcium oxide (PDF 74-1860); iron oxide (PDF 84-0307); aluminum silicon oxide (mullite-synthetic) (PDF 82-1237); calcium
aluminum silicate (anorthite) (PDF 76-0948); silicon oxide (quartz) (PDF 83-2465)

Table 2
The composition of studied AABSIP.

Sample MG wt% Na2B4O7 wt% Fly ash wt% NaOH wt% Distilled water wt%
RB 60 – – 9.3 30.7
MGB 40.5 19.5 – 9.3 30.7
MGBF 36.45 19.5 4.05 9.3 30.7
300 Taha H. Abood Al Saadi et al. / Construction and Building Materials 136 (2017) 298–306

18000 in the oven up to the normal temperature (20 ± 2 °C). Each thermal
NaBO2 .2H2O- PDF 081-1512
treatment experiment was carried out in duplicate.
16000

14000 2.2. Methods


12000
The mineralogical composition of fly ash and AABSIP pastes was
10000 assessed by X ray diffraction (XRD) using a Shimadzu XRD 6000
I (cps)

diffractometer. The XRD spectra were obtained using a monochro-


8000
matic CuKa radiation (k = 1.5406 Å), range 2h from 5 to 50 degree.
6000 The microstructure was assessed with two Scanning Electron
Microscopes (SEM) – Hitachi S2600N and FEI Inspect F50 High Res-
4000
olution. All image captures were performed via secondary electron
2000 detection in high vacuum mode.
The SEM analyses were performed both on fracture and on pol-
0
10 15 20 25 30 35 40 45 50 ished specimens. The polished specimens were obtained by their
2 θ degree surrounding with epoxy resin, curing, cutting and mechanically
polishing with abrasive discs. The polished specimens were used
Fig. 1. XRD patterns of dried gel obtained by mixing sodium hydroxide solution
with anhydrous borax.
for the evaluation of pore structure.
The mass losses of thermally treated pastes were calculated
with the formula:
DM ¼ ½ðMa  Mb Þ=Mb   100 ð%Þ ð1Þ
information about this process, the gel-like phase, resulted after
the addition of anhydrous borax to NaOH solution, was dried at where Ma = specimen’s mass after thermal treatment; Mb = speci-
60 °C for 24 h and analyzed by XRD and SEM. men’s mass before thermal treatment.
Pastes were prepared with the formulation presented in Table 2 The volume change was calculated with the formula:
and cast in prismatic molds (15  15  60 mm); the molds were
covered with cling film and cured for 24 h in an oven at 60 °C, then
DV ¼ ½ðVa  Vb Þ=Vb   100 ð%Þ ð2Þ
de-molded and cured in air at 20 °C up to 7 days. The paste speci- where Va = specimen volume after thermal treatment (cm3);
mens were then subjected to thermal treatment in an electric fur- Vb = specimen volume before thermal treatment (cm3).
nace, at different temperatures (500 °C up to 850 °C) for 1 h. The Hydrolytic stability of AABSIP with/without fly ash was deter-
heating rate was 10 °C/min and the specimens were slow cooled mined with the method used by Vancea and Lazau [18] for the

a b

c d
Fig. 2. SEM micrographs of dried material formed by the mixing sodium hydroxide solution with anhydrous borax.
Taha H. Abood Al Saadi et al. / Construction and Building Materials 136 (2017) 298–306 301

assessment of hydrolytic stability of glass foams; the method is On the XRD patterns of the dried gel, one can assess the specific
described in ISO 719-1985 [19]. This method determines the peaks for sodium metaborate dihydrate (NaBO22H2O). According
hydrolytic resistance of glass grains in hot water and consists in to literature data we assume the formation of sodium metaborate
keeping 2 g of material, for 60 min in 50 ml de-ionized water at tetrahydrate (NaBO24H2O) [20,21] followed by its dehydration,
98 °C. A volume of 25 ml of the obtained solution is titrated with during the thermal treatment at 60 °C, to sodium metaborate dihy-
0.01 M HCl solution. The volume of HCl needed for neutralization drate (NaBO22H2O) [21–23].
is recorded in order to calculate the equivalent Na2O extracted. The SEM micrographs of the dried material are presented in
In order to assess the influence of the fly ash addition and curing Fig. 2.
condition on the specimens behavior during the thermal treat- One can assess in these figures an important amount of
ment, MGB and MGBF paste specimens, after the initial thermal elongated crystals (slim or flat like rod crystals – see arrows in
treatment at 60 °C for 24 h, were cured in an environment satu- Fig. 2b, c) which seems to grow from a phase less structured –
rated with moisture (R.H. 95%) for 30 days. After curing in the see dotted circles (Fig. 2d). One can also assess some plate
humid environment, the specimens were thermally treated at like structures (see arrows in Fig. 2c,d). Both types of crystals/
600 °C and 650 °C and their swelling was visually assessed. Volume structures can be attributed to sodium metaborate dihydrate
changes were also recorded and calculated with formula (2). [24,25]. According to Qin et al. [25] the morphology of sodium
metaborate dihydrate depends on temperature and solution
suprasaturation; plate like crystals forms at high temperatures
3. Results and discussions
(40–50 °C) and elongated crystals forms at lower temperature
(30 °C) – flat rods at low supersaturation and slim rods at high
3.1. Composition and microstructure of AABSIP
supersaturation.
The microstructure of alkali activated inorganic polymers MGB
As previously mentioned the addition of anhydrous borax (Na2-
and MGBF is presented in Figs. 3 and 4.
B4O7) to NaOH solution resulted in the formation of a gel-like
In the microstructure of specimen without fly ash (MGB – Fig. 3)
phase; after the addition of MG or MG + fly ash mixture, the work-
one can assess two distinct phases:
ability of the system rapidly decreased. The increase of viscosity
was mentioned also by Williams and van Riessen [17], but no
- agglomeration of disc shaped or polyhedral particles (Fig. 3a, b)
explanation was provided for this process.
characteristic for aluminosilicate gel [26] or crystalline zeolites
In order to obtain more information, the obtained gel-like phase
[27,28];
resulted after the addition of anhydrous borax to NaOH solution
- thin or flat rod like crystals, similar with those assessed in the
was dried at 60 °C for 24 h (same conditions used for the thermal
dried gel-like phase formed in the reaction of NaOH solution
treatment of AABSIP) and analyzed by XRD and SEM.
with anhydrous borax (Fig. 2).
The XRD pattern of dried gel is presented in Fig. 1.

Fig. 3. SEM micrographs of MGB.


302 Taha H. Abood Al Saadi et al. / Construction and Building Materials 136 (2017) 298–306

a b

c d
Fig. 4. SEM micrographs of MGBF.

NaBO2.2H2O 006-0122 Na2SiO3 082-0604 Na2B4O7.5H2O 007- 0277 and elongated flat rods, without providing and identification of
NaCa2Al5.Si5O20.6H2O 002-0780 (Ca,Na)4Al3(Al,Si)3Si6O24 017-0754 SiO2 083-2466 these phases; according to these authors, in high strength boroalu-
minosilicate binders, the required energy for crack propagation is
divided between the numerous fine elongated crystals.
The presence of sodium metaborate hydrate in these formula-
tions can be benefic for two reasons: i) it is a compound commonly
found in the manufacture of adhesives, therefore it can contribute
I (CPS)

MGB to the increase of the materials’ adherence, coherence and


strength; ii) due to its specific morphology (elongated crystals)
can contribute to the increase of mechanical strength of AABSIP
[15,16].
The X-ray diffraction patterns of MGB and MGBF are presented
MGBF in Fig. 5. The XRD patterns suggests the presence in MGB paste of
different types of sodium (calcium) silicate (aluminate) hydrates
along with a small amount of sodium metaborate hydrate. In the
F
paste with fly ash (MGBF), one can assess also some peaks specific
15 20 25 30 35 40 45 50 55 for SiO2 (quartz) – the main crystalline compound present in fly
2 θ (degree) ash and tincalconite (Na2B4O75H2O).

Fig. 5. XRD spectra of fly ash (F) and AABSIP materials (MGB and MGBF). 3.2. Influence of thermal treatment on the main properties of AABSIP

These data suggests the coexistence of sodium metaborate In order to assess the thermal/fire behavior of these materials,
hydrate with sodium (calcium) silicate (aluminate) compounds paste specimens without borax (RB) and with borax (MGB, MGBF),
with different crystallinity degrees. cured the first day at 60 °C and up to 7 days at 20 °C, were sub-
A similar microstructure is assessed for the paste with fly ash jected to thermal treatment for 1 h at temperatures comprised
content (MGBF) i.e. a mixture of sodium (calcium) silicate (alumi- between 500 °C and 850 °C. The specimens were slow cooled in
nate) phases with different crystallinity degrees and agglomeration the oven.
of plate and elongated crystals (see arrows in Fig. 4c, d) which can The visual aspect of paste specimens, before and after thermal
be attributed to a sodium borate hydrate phase. treatment, is presented in Table 3.
Nazari et al. [15,16] reported also this specific microstructure From the data presented in Table 3, it can be observed that ther-
for boroaluminosilicate geopolymers, with ‘‘star–like needles” mal treatment at 500 °C of the paste without borax (RB) causes the
Taha H. Abood Al Saadi et al. / Construction and Building Materials 136 (2017) 298–306 303

Table 3
The visual aspects of paste specimens before and after thermal treatment at different temperatures (top and side views).

cracking of the sample; when the thermal treatment temperature mines the bending, partial melting and local swelling of the
increases to 650 °C, the specimens starts to alter their shape specimens. An important volume increase is noticed for MGBF
(deformation), swell and the porosity increases. Thermal treatment specimens when is thermally treated at 650 °C.
at 850 °C causes a partial melting of the material at the surface of The microstructure of paste specimens thermally treated at
the specimen (self-glazing) but the internal porosity remain high 500 °C and 650 °C, was assessed by SEM, both in fracture and pol-
(see the side view of the specimen). ished specimens. The SEM images are presented in Fig. 6. For the
For the composition with borax (MGB), the paste specimens specimen without borax (RB), the thermal treatment at 650 °C
starts to bend and swell at a lower temperature i.e. 500 °C; a high leads to the increase of internal porosity (see Fig. 6a); pores with
increase of MGB volume and porosity is noticed when the speci- irregular shapes and sizes comprised between 1 and 50 lm are
men is thermally treated at 600 °C and 650 °C. MGB starts to melt present in this specimen. As reported in previous papers [7,10], this
when thermal treatment is performed at 700 °C. It has to be noted important increase of the porosity is due to the dehydration and
the decrease with approximately 100 °C of the temperature at transformation of sodium silicate (aluminate) hydrates formed by
which these specimens starts to swell and melt as compared with activation of glass powder with NaOH solution. The size of pores
the specimens without borax (RB). formed in the paste with borax (Fig. 6e, f), thermally treated at
The partial substitution of mixed glass powder with fly ash do 500 °C, increases up to 100 lm; for the paste with borax and fly
not substantially modifies the specimens’ behavior at high temper- ash (Fig. 6b, c, d), thermally treated at 650 °C, one can notice the
atures; thermal treatment performed at 500 °C and 600 °C deter- presence of large pores (500 lm up to 1 mm), as well as small
304 Taha H. Abood Al Saadi et al. / Construction and Building Materials 136 (2017) 298–306

Fig. 6. SEM micrographs of paste specimens thermally treated at different temperatures: a) RB 650 °C (fracture); b), c) MGBF 650 °C (fracture) and d) MGBF 650 °C (polished
surface); e) MGB 500 °C (fracture) and d) MGB 500 °C (polished surface).

round pores (5–100 lm) in the walls of the larger pores (Fig. 6c). (aluminate) hydrates formed in this composition due to the partial
The higher porosity of specimens with borax (MGB and MGBF) as substitutions of reactive glass powder with fly ash – with a lower
compared with RB can be explained by the superposition of two reactivity vs. alkaline activator solution [29].
processes that determines the volume and porosity increase: i) As previously presented, the thermal treatment at 600 °C and
the dehydration and transformation of sodium (calcium) silicate 650 °C determines an important volume and porosity increase for
(aluminate) hydrates formed by activation of glass powder with MGB (Table 3 and Fig. 7b). The specimen without borax (RB) shows
NaOH solution and ii) the dehydration and transformation of boron a volume decrease (contraction) when the thermal treatment is
containing phases; Kavas et al. [13] observed, using heating micro- performed at 500 °C and 600 °C and starts to expand after 650 °C
scopy, a continuous release of gases during the thermal treatment – Fig. 7b.
of boron-containing wastes and quartz sand mixtures.
Mass and volume changes of thermally treated specimens were 3.3. Stability in humid environment
calculated with the formulae 1 and 2 (§2.2) and are presented in
Fig. 7. The results obtained in previous studies [6,8,9,29] showed a
Mass losses (over 25%) were recorded for all thermally treated high solubility of alkali activated inorganic polymers based on
specimens (Fig. 7a). This mass loss is due to dehydration of (cal- waste glass powder. This can represent a serious drawback if these
cium) sodium silicate (aluminate) hydrates and sodium borate materials are used for the production of construction materials or
hydrates – for MGB and MGBF specimens. This explains the higher as intumescent materials. Therefore, in this study, was also
mass loss recorded for MGB sample (with 5–15%) as compared assessed the hydrolytic stability of the AABSIP materials; this
with the sample without borax (RB). The smaller mass loss was appreciate considering the amount of Na2O equivalent solubi-
recorded for the specimen with fly ash, as compared with MGB, lized after keeping the material for 60 min in deionized water at
can be due to a lower amount of sodium (calcium) silicate 98 °C [18,19]. The Na2O equivalent values obtained for the pastes
Taha H. Abood Al Saadi et al. / Construction and Building Materials 136 (2017) 298–306 305

a 0 400
MGB 1d/60°C+6d/20°C MGB 1d/60°C+29d(humid air)
MGBF 1d/60°C+6d/20°C MGBF 1d/60°C+29d(humid air)
-5 350

-10 300

-15 250
∆M (%)

V(%)
-20 200

-25
150

-30
100
RB MGB MGBF
-35
50
500°C 600°C 650°C 700°C 850°C

0
b 400
RB MGB MGBF 600°C 650°C
350

300 Fig. 10. Influence of curing medium on the volume changes of AABSIP.

250

200
∆V (%)

150
if the use of these materials is intended as intumescent materials
or for thermal and sound insulations. Therefore, another method
100
was also used in order to evaluate the stability of AABSIP materials
50 in humid environment; as presented in § 2.2, the MGB and MGBF
0
paste specimens cured the first day at 60 °C and then kept in
humid environment (R.H. = 95%) for 30 days; after curing in the
-50
500°C 600°C 650°C humid environment, the specimens were thermally treated at
600 °C and 650 °C and their swelling was visually assessed and
Fig. 7. Mass loss (a) and volume change (b) of RB and AABSIP (MGB, MGBF) pastes compared with the swelling of MGB and MGBF cured in air
after thermal treatment at different temperatures.
(R.H. = 45%) and thermally treated at the same temperatures –
Figs. 8 and 9.
The curing of MGB (without fly ash) for 29 days in moisture
room (95% R.H.) has a negative influence on the volume (and
cured 7 days (1 day at 60 °C and 6 days at 20 °C) are higher for
porosity) increase recorded when the specimens are thermally
AABSIP without fly ash i.e. 177 mg/g (MGB) and 121 mg/g (MGBF);
treated (Figs. 8 and 10).
nevertheless, these values are very high suggesting a high solubil-
For the geopolymer with fly ash addition (MGBF – Figs. 9 and
ity of the materials in water explained both by the presence of
10), curing in moist air (R.H.95%) has a lower influence
sodium silicate (aluminate) hydrates as well as borate phases with
(as compared with MGB) and it is probably due to improved
high solubility in water [30].
hydrolytic stability when in the system is introduced fly
However, the previous method used for the assessment of
ash.
hydrolytic stability is too aggressive (solubilization in hot water)

MGB (cured in humid environment) MGB (cured in air)


Fig. 8. MGB after thermal treatment at 600 °C for 1 h.

MGBF (cured in humid environment) MGBF (cured in air)


Fig. 9. MGBF after thermal treatment at 650 °C for 1 h.
306 Taha H. Abood Al Saadi et al. / Construction and Building Materials 136 (2017) 298–306

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