From marble waste to monocarboaluminate binder: role of sodium aluminate composition, calcined clay type, and curing temperature

This study focuses on the synthesis of a monocarboaluminate (MCA)-based binder by treating marble waste (MW) powder with sodium aluminate (SA). The aim is to investigate the influence of various parameters, including the alumina modulus (M_A) of SA, different contents of calcined clays with varying alumina levels, and curing temperatures, on the performance and phase composition of the resulting binder. The results demonstrate that the combination of SA and MW leads to the formation of an MCA-based binder, which exhibits a high compressive strength of up to 28 MPa after seven days of curing. Additional phases such as gibbsite, pirssonite, and gaylussite are observed, indicating the occurrence of a cationic exchange reaction between MW and SA, as confirmed by X-ray diffraction (XRD) and Fourier transform infrared spectroscopy (FT-IR). The stability of the resulting binder is primarily influenced by the M_A value, with higher values associated with greater stability. Regardless of the type of calcined clay used, incorporating calcined clay results in the formation of a calcium aluminate silicate hydrate (CSAH) phase alongside MCA, contributing to the improved stability of the hardened binder over time. Notably, calcined clay with a higher alumina content exhibits the highest strength at all curing ages. Furthermore, increasing the curing temperature up to 100 °C significantly enhances the early strength, which correlates with the formation of the kotoite phase at the expense of the MCA phase.