Feasibility of alkali-activated mining waste foamed materials incorporating expanded granulated cork

Different combinations of mining waste mud, grounded waste glass, Portland cement, metakaolin and expanded cork were mixed together with alkaline activators (sodium silicate and sodium hydroxide solution) and as well aluminum powder or hydrogen peroxide to produce foamed lightweight materials. The size of the mineral materials is under 500 µm and expanded cork particles size is between 2 to 4 mm. The expanded cork added to the mixes changed between 10 to 40% volume of total solids. The influence of expanded cork on compressive strength was investigated. Precursors and activators were mixed together to produce a homogeneous mixture, which was placed into a cubic mold (40 x 40 x 40 mm³), and cured at a temperature of 60°C, for 24 hours. After curing process, samples without foaming agents achieved the maximum compressive strength of 14.7 and 19.5 MPa for 7 and 28 days respectively. The porosity was observed by the naked eye of large voids in a range of 4 mm in size. Microstructure analyses were carried on by SEM. Samples made with aluminum powder showed higher volume increase about 358% compared with samples made with hydrogen peroxide that presented a 141% volume increase. This preliminary study shows the feasibility to produce new improved lightweight foamed alkali activated materials incorporating expanded cork with potential applications in artistic, architectural, and historical heritage restoration.