Alkali-Activated Copper Slag with Carbon Reinforcement: Effects of Metakaolinite, OPC and Surfactants

Copper slag is an industrial residue with a large unutilized fraction. This study presents the development of alkali-activated composites from a copper slag named Koranel®. The effects of metakaolinite, ordinary Portland cement (OPC) and surfactants were investigated. The reactivity of Koranel with potassium silicate solutions with molar ratio R = SiO2/K2O varying from 1 to 2.75, with 0.25 intervals, was investigated using isothermal calorimetry. The reactivity was relatively low at 20 °C; the reaction started after a few hours with a low silica modulus, to several weeks with the highest silica modulus. The substitution of Koranel by OPC (5 wt.%) or by metakaolinite (10–20 wt.%), both led to higher reaction heat and rate; meanwhile, the addition of 2 wt.% polyethylene glycol/2-methyl 2,4 pentanediol delayed the reaction time in the system containing metakaolinite. Raising the curing temperature from 20 °C to 80 °C shortened the setting time of the low reactive systems, from several days to almost instantaneous, opening perspectives for their application in the production of prepreg composite materials. The use of carbon fabric as reinforcement in the alkali-activated matrix led to composite materials with flexural strength reaching 88 MPa and elastic modulus of about 19 GPa—interesting for engineering applications such as high-strength lightweight panels.