Performance optimization design of high ductility cement-based alkali-activated municipal solid waste incineration fly ash composite for rapid repair material

•Mechanism of the municipal solid waste incineration fly ash (MSWIFA)-cement hydration process at the early-age was revealed.•Mix proportation of MSWIFA-SAC cementitious system at the early age is proposed.•Heavy metal ions in the MSWIFA were solidified.•Mixture proportation of High Ductility SAC Rapid Repair Material (HD-SACRRM) is advised. As a residue that results from the high-temperature incineration of urban household waste, municipal Solid Waste Incineration Fly Ash (MSWIFA) contains various harmful organic pollutants like dioxins and heavy metals. These contaminants pose significant health risks to humans, including deformities and carcinogenic effects. The focus of this study is the development of a High Ductility SAC Rapid Repair Material (HD-SACRRM) through MSWIFA as a partial replacement for Sulphate Aluminate Cement (SAC), so as to achieve high ductility, rapid hardening, and the strength required for pavement layers. The reactivity of MSWIFA is investigated by adjusting its content and the type and dosage of alkali-activators. X-Ray Diffraction (XRD) and Scanning Electron Microscopy (SEM) tests are conducted to analyze the variety and microstructure of alkali-activated MSWIFA-SAC hydration products. Also, the efficiency of immobilizing heavy metal ions within the alkali-activated system is examined. Based on these findings, the proportions of HD-SACRRM are optimized. The experimental results demonstrate that the optimal conditions for MSWIFA reactivity are met when the MSWIFA content is 20% and the 30% soluble silicate with a modulus of 1.8 is present. The optimized conditions of HD-SACRRM are as follows: a 20% MSWIFA content, 30% soluble silicate with a modulus of 1.8, a water-cement ratio of 0.30, a 2.0% fiber volume fraction, a sand-cement ratio of 0.30, and 5% Li2CO3 as an early strength agent. After 48 h of curing as standard, the material exhibits a compressive strength of 45.7 MPa, an ultimate elongation of 2.70%, and an average crack width of 127.59 μm. The alkali-activated MSWIFA-SAC system generated more gels such as C-S-H and C-A-H, thus resulting in a dense microstructure that enhances both the capacity of heavy metal immobilization and mechanical strength. These findings shed some light on the recycling of MSWIFA solid waste and the repair of asphalt concrete road surfaces.