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Journal of Polymer & Composites Original Research

Optimized Utilization of Kota Stone Slurry Waste in Fly Ash–Based Geopolymer Mortar: A Taguchi-Driven Approach

  1. Pawan Patidar Department of Civil Engineering, Malaviya National Institute of Technology, Jaipur
  2. Pawan Kalla Department of Civil Engineering, Malaviya National Institute of Technology, Jaipur
  3. Pravesh Saini Department of Civil Engineering, Malaviya National Institute of Technology, Jaipur

Abstract

The large-scale generation of stone-processing wastes presents a critical sustainability challenge and an opportunity for value-added reuse in construction materials. This study develops a high-performance fly ash geopolymer mortar by partially replacing Class F fly ash with Kota stone slurry waste (KSSW) and optimizing the key mix parameters using a Taguchi design framework. Five governing factors—binder replacement level, NaOH molarity, sodium silicate–to–sodium hydroxide ratio (SS/SH), curing temperature, and alkaline solution-to-binder ratio (A/B)—were systematically optimized using ultrasonic pulse velocity (UPV; larger-the-better) and water absorption (smaller-the-better) as primary compactness and durability indicators, with strength confirmation. The optimum combination (25% KSSW, 12 M NaOH, SS/SH = 1, curing at 60 °C, A/B = 0.5) achieved a UPV of 4380 m/s (+16.7%) and a minimum water absorption of 3.1% (−63.9%) relative to the control, indicating substantial matrix densification. Correspondingly, compressive and flexural strengths reached 25.6 MPa (+143.8%) and 3.95 MPa (+62.6%) at 28 days. Regression modelling and ANOVA confirmed curing temperature as the dominant factor, while excessive activator content adversely affected performance. Durability evaluation of the control and optimum mixes showed progressive degradation under acid exposure, whereas sulphate immersion up to 90 days resulted in net strength gain with early mass increase (pore filling) followed by slight mass loss at longer exposure; drying shrinkage remained comparable between mixes (≈0.00158 at 90 days), indicating no shrinkage penalty for the optimized system. Multi-scale characterization (XRD, SEM–EDS elemental mapping, FTIR, XRF, and TGA/DTG–DSC) supported improved gel development and Ca-assisted densification in the KSSW-modified matrix. Overall, the results establish KSSW as a viable supplementary binder and demonstrate that strength-driven statistical optimization enables a resource-efficient, high-performance geopolymer mortar suitable for sustainable construction applications.

Keywords

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