Reaction Mechanisms and Early-Stage Properties of Sustainable Calcium Carbide Residue-Granulated Blast Furnace Slag-Fly Ash Alkali-Activated Composites

Infrastructure maintenance and emergency repairs require rapidly setting cementitious materials, yet conventional cement presents issues of high energy consumption and substantial CO2 emissions. Addressing this challenge, this research has developed a ternary alkali-activated cementitious material (CGFM) composed of calcium carbide residue (CCR), granulated blast furnace slag and fly ash. This study separately investigates the effects of CCR content (0–10%), alkali content (6–12%) and activator modulus (1.0–1.5) on workability and early mechanical strength. The hydration mechanism was examined through X-ray Diffraction (XRD), Fourier Transform Infrared (FTIR), Thermogravimetry-Derivative Thermogravimetry (TG-DTG) and Scanning Electron Microscopy-Energy Dispersive Spectroscopy (SEM-EDS) analysis, whilst life cycle assessment was employed to quantify the ecological impacts. Results indicated that a 3% CCR dosage significantly improved the gel structure, achieving a 7-day compressive strength of 69.8 MPa and a 37% increase in flexural strength. At a CCR dosage of 3%, alkali content of 8%, and modulus of 1.4, CGFM achieved a peak compressive strength of 80.2 MPa by the seventh day. This performance is attributable to its substantial gel content and high degree of polymerisation, which results in a dense structure. Life cycle assessment confirmed that compared to sulphoaluminate cement mortar, CGFM mortar reduced CO2 emissions by 64.6% and energy consumption by 48.6%.