Experimental Investigation on Factors Influencing the Early-Age Strength of Geopolymer Paste, Mortar, and Concrete

This study systematically investigates the key parameters governing the mechanical performance of fly ash-based geopolymer across paste, mortar, and concrete scales. Comprehensive mechanical testing, combined with SEM and MIP analyses, elucidated the relationships between activator composition, pore structure, and strength development. A key innovation is the development of a cross-scale quantitative framework linking mortar strength to concrete compressive strength, enabling preliminary predictive capability across material scales. Grey relational analysis identified curing temperature as the most influential factor, followed by SiO₂/Na₂O and H₂O/Na₂O ratios. Thermal curing accelerates strength development and temperatures of 70~80 °C markedly enhance reaction rates. Both compressive and flexural/splitting tensile strengths increase and then decrease with NaOH concentration or sodium silicate modulus, with optimal performance at 24~26% NaOH and SiO₂/Na₂O ratio of 1.2~1.4, while increasing H₂O/Na₂O reduces strength nearly linearly, constrained by workability. Concrete compressive strength rises with coarse aggregate content up to 60~70% before declining. SEM and MIP confirm that optimal activator formulations produce a dense, homogeneous gel matrix with lower porosity and fewer unreacted particles. Strong square-root correlations between compressive and tensile-related strengths were observed across all material systems. Overall, this work establishes a quantitative foundation for geopolymer mix design and provides actionable guidance for developing high-performance, low-carbon geopolymer concrete.