Development of innovative alkali activated paste reinforced with polyethylene fibers for concrete crack repair

Concrete structures are susceptible to cracking, which can compromise their integrity and durability. Repairing them with ordinary Portland cement (OPC) paste causes shrinkage cracks to appear in the repaired surface. Alkali-activated binders offer a promising solution for repairing such cracks. This study aims to develop an alkali-activated paste (AAP) and investigate its effectiveness in repairing concrete cracks. AAPs, featuring varying percentages (0.5%, 0.75%, 1%, 1.25%, 1.5%, and 1.75%) of polyethylene (PE) fibers, are found to exhibit characteristics such as strain hardening, multiple plane cracking in tension and flexure tests, and stress-strain softening in compression tests. AAP without PE fibers experienced catastrophic failure in tension and flexure, preventing the determination of its stress-strain relationship. Notably, AAPs with 1.25% PE fibers demonstrated the highest tensile and flexural strength, exceeding that of 0.5% PE fiber reinforced AAP by 100% in tension and 70% in flexure. While 1% PE fibers resulted in the highest compressive strength, surpassing AAP without fibers by 17%. To evaluate the repair performance of AAP, OPC cubes were cast with pre-formed cracks. These cracks were induced by placing steel plates during casting and were designed to be full and half-length with widths of 1.5 mm and 3 mm. AAP both with and without PE fibers led to a substantial improvement in compressive strength, reducing the initial strength loss of 30%-50% before repair to a diminished range of 2%-20% post-repair. The impact of PE fiber content on the compressive strength of repaired OPC cube is marginal, providing more flexibility in using AAP with any fiber percentage while still achieving effective concrete crack repair. Considering economic and environmental factors, along with observed mechanical enhancements, AAPs show promising potential for widespread use in concrete repair and related applications, contributing valuable insights to the field of sustainable construction materials.