Sustainable Concrete Production Using Granodiorite, Alkali Feldspar Granite, and Mafic Metavolcanic Rock Powders as Supplementary Cementitious Materials
Abstract
1. Introduction
Research Significance
2. Materials
2.1. Cement
2.2. Aggregates
2.3. Water and Superplasticizer
2.4. Rock Powders
2.4.1. Granodiorite Powder (GDP)
2.4.2. Alkali Feldspar Granite Powder (AFGP)
2.4.3. Mafic Metavolcanic Powder (MMVP)
3. Experiments
3.1. Mix Design and Mixing Procedures
3.2. Casting and Curing
3.3. Test Methods
3.3.1. Strength Activity Index (SAI)
3.3.2. Workability
3.3.3. Mechanical Properties
3.3.4. Microstructural Analysis
4. Experimental Results
4.1. SAI (%)
4.2. Slump Test Result
4.3. Mechanical Properties Results
4.3.1. Compressive Strength
4.3.2. Splitting Tensile Strength
4.4. Microstructural Analysis Results
4.4.1. SEM Analysis
4.4.2. EDX Analysis
5. Conclusions and Future Studies
- All three rock powders demonstrated favorable pozzolanic characteristics, with combined oxide contents (SiO2 + Al2O3 + Fe2O3) of 88.21%, 88.61%, and 78.44% for GDP, AFGP, and MMVP, respectively, significantly exceeding ASTM C618 requirements for natural pozzolans. These values, coupled with SAI values of 79%, 82%, and 76% for GDP, AFGP, and MMVP, respectively—all surpassing the 75% minimum threshold—confirm that chemical composition alone is insufficient for pozzolanic classification, and that mechanical activity indices provide essential complementary validation.
- Workability progressively decreased with increasing rock powder content due to their ultrafine particle sizes (1.4–1.5 μm) and elevated specific surface areas (11,800–13,050 cm2/g), though all mixtures maintained acceptable slump values above 60 mm for practical construction applications. This trade-off between workability and reactivity is an inherent characteristic of ultrafine SCMs and should be considered in mix design optimization, particularly for applications requiring high flowability.
- The optimal replacement levels varied by powder type: 9% for GDP and AFGP, and 6% for MMVP—a difference attributed to the lower combined oxide content and higher MgO and Fe2O3 content of MMVP, which limits its optimal dosage compared to the more felsic GDP and AFGP. At these dosages, compressive strength improvements of 14.1%, 16.0%, and 14.9% were achieved at 28 days, while splitting tensile strength increased by 14.7%, 12.7%, and 16.3%, respectively, compared to the control mixture. These improvements are comparable to those reported for well-established SCMs such as Class F fly ash and natural pozzolans, confirming the competitive performance potential of Eastern Desert rock powders.
- SEM analysis revealed that rock powder incorporation substantially improved microstructural characteristics through dual mechanisms: physical filler effects reducing porosity and void content, and chemical pozzolanic reactions generating additional C-S-H gel formation, resulting in denser, more homogeneous matrices.
- EDX analysis confirmed reduced Ca/Si ratios (1.37, 1.23, and 1.13 for GD9, AFG9, and MMV6 versus 2.89 for control), consistent with enhanced C-S-H gel formation in pozzolanic systems. The inverse correlation between Ca/Si ratio and compressive strength is corroborated by the SAI results, collectively providing multi-scale evidence of pozzolanic reactivity.
6. Limitations and Future Studies
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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| Physical Properties | Mortar Compressive Strength (MPa) | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| Color | Specific gravity | Initial setting time (min) | Final setting time (min) | Standard consistency (w/c%) | Average particle size (μm) | Surface area (cm2/g) | 3 days | 7 days | 28 days |
| Grey | 3.15 | 110 | 190 | 28% | 18 | 3050 | 26 | 34 | 44 |
| SiO2 | CaO | Al2O3 | Fe2O3 | MgO | SO3 | Na2O | K2O | P2O5 | Mn2O3 | TiO2 | LOI * | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| OPC | 21.72 | 60.59 | 4.85 | 1.91 | 2.27 | 2.8 | 0.56 | 0.42 | 0.22 | 0.17 | 0.55 | 3.15 |
| GDP | 68.98 | 3.18 | 15.71 | 3.52 | 1.58 | 0.08 | 3.14 | 2.08 | 0.08 | 0.09 | 0.51 | 0.91 |
| AFGP | 73.23 | 0.91 | 13.91 | 1.47 | 0.55 | 0.05 | 2.78 | 5.86 | 0.11 | 0.03 | 0.18 | 0.88 |
| MMVP | 52.82 | 5.99 | 15.25 | 10.37 | 7.76 | ----- | 3.82 | 0.76 | 0.30 | 0.22 | 0.78 | 1.93 |
| Property | Specific Gravity | Bulk Density (kg/m3) | Voids (%) | Absorption (%) | Clay and Fine Materials (%) | Crushing Value (%) | Fineness Modulus |
|---|---|---|---|---|---|---|---|
| Fine Aggregate | 2.5 | 1730 | 30.8 | 1.5 | 1 | -- | 2.27 |
| Coarse Aggregate | 2.6 | 1430 | 45 | 1.5 | 0.5 | 24 | -- |
| Property | GDP | AFGP | MMVP | ASTM C618 Requirement for Natural Pozzolan |
|---|---|---|---|---|
| (SiO2 + Al2O3 + Fe2O3) % | 88.21 | 88.61 | 78.44 | minimum = 70 |
| SO3% | 0.08 | 0.05 | ---- | maximum = 4 |
| Loss on ignition% | 0.91 | 0.88 | 1.93 | maximum = 10 |
| Color | Light gray | Light pink | Gray | ---- |
| Specific gravity | 2.70 | 2.62 | 2.79 | ---- |
| Average particle size (µm) | 1.4 | 1.5 | 1.5 | ---- |
| Surface area (cm2/g) | 13,050 | 11,800 | 12,100 | ---- |
| Mix | Symbol | Cement | GDP | AFGP | MMVP | Aggregate | Water | SP | |
|---|---|---|---|---|---|---|---|---|---|
| Coarse | Fine | ||||||||
| Control | CO | 400 | ---- | ---- | ---- | 1200 | 620 | 160 | 5 |
| 3% GDP | GD3 | 388 | 12 | ---- | ---- | 1200 | 620 | 160 | 5 |
| 6% GDP | GD6 | 376 | 24 | ---- | ---- | 1200 | 620 | 160 | 5 |
| 9% GDP | GD9 | 364 | 36 | ---- | ---- | 1200 | 620 | 160 | 5 |
| 12% GDP | GD12 | 352 | 48 | ---- | ---- | 1200 | 620 | 160 | 5 |
| 3% AFGP | AFG3 | 388 | ---- | 12 | ---- | 1200 | 620 | 160 | 5 |
| 6% AFGP | AFG6 | 376 | ---- | 24 | ---- | 1200 | 620 | 160 | 5 |
| 9% AFGP | AFG9 | 364 | ---- | 36 | ---- | 1200 | 620 | 160 | 5 |
| 12% AFGP | AFG12 | 352 | ---- | 48 | ---- | 1200 | 620 | 160 | 5 |
| 3% MMVP | MV3 | 388 | ---- | ---- | 12 | 1200 | 620 | 160 | 5 |
| 6% MMVP | MV6 | 376 | ---- | ---- | 24 | 1200 | 620 | 160 | 5 |
| 9% MMVP | MV9 | 364 | ---- | ---- | 36 | 1200 | 620 | 160 | 5 |
| 12% MMVP | MV12 | 352 | ---- | ---- | 48 | 1200 | 620 | 160 | 5 |
| Mix Code | Compressive Strength (7 Days) | Compressive Strength (28 Days) | Compressive Strength (90 Days) | Splitting Tensile Strength (28 Days) | ||||
|---|---|---|---|---|---|---|---|---|
| Mean ± SD (MPa) | CV (%) | Mean ± SD (MPa) | CV (%) | Mean ± SD (MPa) | CV (%) | Mean ± SD (MPa) | CV (%) | |
| CO | 26.4 ± 1.6 | 6.1 | 36.9 ± 3 | 8.18 | 40.3 ± 3.7 | 9.12 | 3.07 ± 0.28 | 9.25 |
| GD3 | 27.7 ± 2.7 | 9.71 | 38.4 ± 1.5 | 3.94 | 42.7 ± 2.1 | 4.92 | 3.28 ± 0.32 | 9.71 |
| GD6 | 29.6 ± 1.7 | 5.89 | 40.7 ± 2.4 | 5.87 | 44.3 ± 2.3 | 5.16 | 3.33 ± 0.32 | 9.48 |
| GD9 | 31 ± 2.1 | 6.74 | 42.1 ± 2.9 | 6.85 | 48.2 ± 1.9 | 3.94 | 3.52 ± 0.27 | 7.79 |
| GD12 | 29.2 ± 2.2 | 7.65 | 38 ± 1.9 | 4.87 | 42.5 ± 2.5 | 5.88 | 3.36 ± 0.21 | 6.12 |
| AFG3 | 27.3 ± 2 | 7.35 | 38.9 ± 2.3 | 5.84 | 44.1 ± 3.7 | 8.43 | 3.23 ± 0.26 | 8.17 |
| AFG6 | 28.6 ± 1.7 | 5.82 | 39.4 ± 2.8 | 7.04 | 44.7 ± 3.1 | 6.99 | 3.42 ± 0.30 | 8.88 |
| AFG9 | 30.3 ± 2.7 | 9.07 | 42.8 ± 1.5 | 3.6 | 46.3 ± 3.5 | 7.49 | 3.46 ± 0.29 | 8.42 |
| AFG12 | 28.1 ± 1.2 | 4.27 | 39.3 ± 0.9 | 2.33 | 44 ± 1.4 | 3.28 | 3.21 ± 0.12 | 3.61 |
| MMV3 | 29 ± 1.1 | 3.63 | 39.5 ± 2.3 | 5.93 | 43.7 ± 1.6 | 3.55 | 3.40 ± 0.15 | 4.51 |
| MMV6 | 29.8 ± 1.7 | 5.7 | 42.4 ± 3.5 | 8.2 | 46.1 ± 3.7 | 8.1 | 3.57 ± 0.26 | 7.24 |
| MMV9 | 27.4 ± 1.3 | 4.79 | 41.3 ± 1.6 | 3.9 | 44.1 ± 1.3 | 2.9 | 3.25 ± 0.12 | 3.57 |
| MMV12 | 25.8 ± 1 | 3.7 | 37.8 ± 2.9 | 7.57 | 42.3 ± 4.2 | 9.87 | 2.90 ± 0.17 | 5.9 |
| Mix | Composition wt% | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| C K | O K | Mg K | Al K | Si K | Ca K | Fe K | Ti K | K | S K | Na K | Ca/Si | |
| CO | 9.26 | 52.58 | ------ | 1.17 | 8.89 | 25.66 | 1.17 | ------ | ------ | 1.27 | ------ | 2.89 |
| GD9 | 5.99 | 46.88 | ------ | 0.57 | 18.56 | 25.48 | 1.38 | ------ | ------ | 1.14 | ------ | 1.37 |
| AFG9 | 8.32 | 44.69 | ------ | 0.55 | 19.88 | 24.45 | 1.62 | ------ | ------ | ------ | 0.5 | 1.23 |
| MMV6 | 12.01 | 49.68 | 0.64 | 4.14 | 13.31 | 15.09 | 3.42 | 0.25 | 1.47 | ------ | ------ | 1.13 |
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Faried, A.S.; Fathy, N.; Morsi, W.M.; Dawoud, M.; Mahmoud, A.S.; Osman, K.M. Sustainable Concrete Production Using Granodiorite, Alkali Feldspar Granite, and Mafic Metavolcanic Rock Powders as Supplementary Cementitious Materials. Materials 2026, 19, 2193. https://doi.org/10.3390/ma19112193
Faried AS, Fathy N, Morsi WM, Dawoud M, Mahmoud AS, Osman KM. Sustainable Concrete Production Using Granodiorite, Alkali Feldspar Granite, and Mafic Metavolcanic Rock Powders as Supplementary Cementitious Materials. Materials. 2026; 19(11):2193. https://doi.org/10.3390/ma19112193
Chicago/Turabian StyleFaried, A. Serag, Nourhan Fathy, W. M. Morsi, Maher Dawoud, Abdelhalim S. Mahmoud, and Khaled M. Osman. 2026. "Sustainable Concrete Production Using Granodiorite, Alkali Feldspar Granite, and Mafic Metavolcanic Rock Powders as Supplementary Cementitious Materials" Materials 19, no. 11: 2193. https://doi.org/10.3390/ma19112193
APA StyleFaried, A. S., Fathy, N., Morsi, W. M., Dawoud, M., Mahmoud, A. S., & Osman, K. M. (2026). Sustainable Concrete Production Using Granodiorite, Alkali Feldspar Granite, and Mafic Metavolcanic Rock Powders as Supplementary Cementitious Materials. Materials, 19(11), 2193. https://doi.org/10.3390/ma19112193

