Novel utilization of fly ash for high-temperature mortars: Phase composition, microstructure and performances correlation

In this study, the feasibility of using fly ash to manufacture high-temperature mortars was investigated. The investigation was set to define preliminary characteristics of new types of mortars based on ordinary and/or refractory cement with fly ash addition, and to establish mutual correlation between thermally induced changes of mineral phases, microstructure, and final performances of the mortars. New mortars, made up of 21% cement (PC-CEM I 42.5R/HAC-Secar 70/71), 70% river sand, and 9% fly ash, were chemically, physically, and mechanically characterized to determine possibilities of fly ash re-utilization for high-temperature purposes. The fly ash samples, which originated from four different power plants, were mechanically activated. Mortars were heat-treated up to 1300°C in a laboratory tunnel furnace with retention time 2 h. Thermal stability of crystalline phases were studied by differential thermal analysis (DTA); thermally induced changes in mineral phase composition were analyzed by XRD; and microstructure were investigated by scanning electron microscopy. Correlated results of DTA, XRD, and SEM analyses indicated initiation of sintering processes at approximately 1300°C and formation of thermally stable minerals (rankinite, gehlenite, anorthite, cristobalite). The investigation highlights a sustainable approach of using fly ash in developing ecofriendly mortars for high-temperature application. © 2013 The American Ceramic Society