Sustainable zero cement-based one-part ambient cured alkali-activated engineered composites (AAECs) are developed. The durability and microstructural characteristics of developed AAECs using 2% v/v polyvinyl alcohol (PVA) fibers, silica sand, binary or ternary combinations of precursors (fly ash class C 'FA-C', fly ash class F 'FA-F' and ground granulated blast furnace slag 'GGBFS') and two types of powder form alkaline reagents (Type 1 and Type 2) are evaluated compared to conventional engineered cementitious composites (ECCs) and alkali-activated mortars (AAMs) without fiber. AAECs developed satisfactory compressive strength ranging from 34 MPa to 46 MPa. Expansion/shrinkage and mass change (loss/gain) behaviors are affected by binary/ternary combination of source materials, reagent types and curing regimes (water or ambient) for both AAMs and AAECs. The binary (FA-C + GGBFS) and reagent 2 (calcium hydroxide + sodium sulfate) composites demonstrated lower shrinkage due to formation of crystalline C-A-S-H/C-S-H binding phases than their ternary (FA-C + FA-F + GGBFS) and reagent 1 (calcium hydroxide + sodium metasilicate) counterparts which formed amorphous N-C-A-S-H/N-A-S-H phases. The matrix densification due to the formation of reaction products and fiber-induced micro-confinement leads to lower shrinkage and mass change of AAECs compared to their AAM counterparts. Composites exhibited lower or comparable secondary sorptivity indices compared to control ECC, indicating their superior permeation performance. All AAECs had a relative dynamic modulus of elasticity (RDME) greater than 90% at 300 cycles (comparable to control ECC), exhibiting satisfactory freeze-thaw resistance with reagent 2 mixes showing better performance compared to those with reagent 1. The production feasibility of strain hardening AAECs with powder form reagents having satisfactory mechanical and durability properties is confirmed.
Keywords: alkali-activated engineered composite; fiber; industrial wastes; microstructure; powder form reagents; shrinkage/permeation/freeze–thaw durability.