An efficient solution to increase the sustainability of building materials is to replace Portland cement with alkali-activated materials (AAM). Precursors for those systems are often based on water-cooled ground granulated blast furnace slags (GGBFS). Quenching of blast furnace slag can be done also by air but in that case, the final product is crystalline and with a very low reactivity. The present study aimed to evaluate the cementitious properties of a mechanically activated (MCA) air-cooled blast furnace slag (ACBFS) used as a precursor in sodium silicate alkali-activated systems. The unreactive ACBFS was processed in a planetary ball mill and its cementing performances were compared with an alkali-activated water-cooled GGBFS. Mixes based on mechanically activated ACBFS reached the 7-days compressive strength of 35 MPa and the 28-days compressive strength 45 MPa. The GGBFS-based samples showed generally higher compressive strength values.

The efficiency of the mechanochemical activation (MCA) is influenced by various process parameters as well as by the properties of the treated material. The main objective of this research was to optimize the MCA process, gaining enhancement of the chemical reactivity of a Swedish raw clay, which is going to be used as an alkali-activated cementitious binder. The effects of the amount of water, the filling ratio, the rotation speed, and the grinding duration on the amorphization degree were evaluated by X-Ray Diffraction (XRD) and Scanning Electron Microscopy (SEM). Generally, wet and dry processes showed an extensive amorphization of both kaolinite and muscovite minerals present in the studied clay. On the contrary, quartz was amorphized mainly by the wet grinding process. The efficiency of both dry and wet grinding processes was enhanced by the increased number of grinding media versus the amount of the activated material. However, longer processing times caused significant agglomeration while a higher rotational speed enhanced the amorphization. Preliminary tests have shown that alkali activation of the processed clays produced hardened samples. Furthermore, the increased amorphization corresponded to the increased compressive strength values.

High-temperature requirements, emission of hazardous substances from cement kilns and the significant CO2 footprint in the calcination step are factors requiring special attention in the cement industry. Local and commonly occurring clays can be a sustainable alternative for producing cementitious binders. Structural disorder in natural clay minerals can be induced through mechanochemical activation (MCA), by which the material develops an enhanced reactivity. The treatment of a Swedish natural clay through intensive grinding is carried out in order to assess its potential as a sustainable cementitious binder. Several grinding parameters influence a MCA product. The filling ratio of the jar, the rotation speed, the time of grinding, as well as wet and dry environment, are variated to optimize the MCA process. The MCA process doesnot require high temperatures or added chemicals and shorter processing times can avoid high-energy requirements during fine grinding. The structural changes of the clay were analysed by X-Ray Diffraction (XRD). Analysis of the particle size distribution of the raw and processed clay suggested a correlation with the grinding duration. An increased ratio of grinding media versus the amount of ground material, while longer grinding duration increased the overall efficiency of the MCA process. The strength activity index (SAI) indicated an enhanced pozzolanic activity for the mechanochemically processed clay. Compressive strength tests have shown a strong correlation between an enhanced amorphization rate and increased compressive strength values.

Mechanical activation in a planetary ball mill (BM) is an environmentally friendly process able to enhance the chemical and pozzolanic activity of natural clays. Those materials can be used as supplementary cementitious materials (SCMs) to partially replace Portland cement in concrete. The process parameters of the BM are directly related to the degree of amorphization and thus to the enhancement of the chemical activity. Design of experiments (DOE) is a well-known statistical tool, which can assist in selecting optimized conditions and in obtaining systematic data. However, full factorial design requires a large number of experiment. Taguchi method is based on the use of an Orthogonal Array (OA) to evaluate optimization of the selected factors but with less required experiments. In this study, three factors, each on 2 levels, were selected: ball to powder ratio (B/P) with level 3 and 25, time of grinding with level 5 and 20, and water to powder ratio (W/P) with level 0 and 1. The degree of amorphization (DOA) was selected as the main response for the Taguchi method. DOA was calculated as the ratio between the integral intensities of the main peak of the kaolinite [001] before and after grinding. For dry grinding, the predicted optimized value of DOA complied with the experimental results. Maximized DOA value was achieved for B/P equal to 25 and the grinding duration of 20. This method can be a valuable tool to predict the amorphization degree of minerals present in the natural clay, leading to the optimization of the mechanical activation process.

Mechanochemical activation can be defined as a process able to induce structural disorder through intensive grinding. In certain conditions, it may increase the chemical reactivity of the processed material. The process is extensively utilized in extractive metallurgy, synthesis of nanocomposites or pharmacology. It is also considered an environmentally friendly alternative to activate kaolinitic clay avoiding high calcination temperature. This paper aims to give a comprehensive overview of the process, its evolution, process parameters and applications. The paper focuses on the mechanochemical treatment of natural clay minerals, aiming at their transformation into cementitious or pozzolanic materials. It provides a summarized review of the theories related to the mechanochemistry and discusses commonly used models. The paper also analyzes various key factors and parameters controlling the mechanochemical activation process. The optimization and control of the several factors, as the filling ratio, the grinding media, the velocity, the time of grinding, etc., can promote developments and new research opportunities on different fields of application. Examples of applications, with a special focus on mechanochemically activated clay minerals and their use as cementitious binders, are listed as well.

Replacement of cement with supplementary cementitious materials (SCMs) is a proven method to reduce clinker in cement and contribute to decreased CO₂ emissions. Natural clays are commonly occurring materials that do not possess pozzolanic activity in their original state. Mechanochemical activation (MCA) can be an alternative and sustainable method to enhance their reactivity. In this study, the pozzolanic reactivity of three natural clays, originating from Sweden, was analyzed after the application of MCA in a planetary ball mill. Strength activity index (SAI), Frattini test, and conductivity test were used to evaluate the pozzolanic reactivity. All processed clays by MCA have achieved a SAI greater than 100%, while the Frattini test indicated an improved pozzolanic activity of samples containing a higher amount of clay minerals. The obtained results show that MCA could improve the pozzolanic reactivity, but the effect depends on the mineralogical composition and particle size of the clays.