Natural Clay in Geopolymer Concrete: A Sustainable Alternative Pozzolanic Material for Future Green Construction—A Comprehensive Review

The ordinary Portland cement (OPC) manufacturing process is highly resource-intensive and contributes to over 5% of global CO₂ emissions, thereby contributing to global warming. In this context, researchers are increasingly adopting geopolymers concrete due to their environmentally friendly production process. For decades, industrial byproducts such as fly ash, ground-granulated blast-furnace slag, and silica fume have been used as the primary binders for geopolymer concrete (GPC). However, due to uneven distribution and the decline of coal-fired power stations to meet carbon-neutrality targets, these binders may not be able to meet future demand. The UK intends to shut down coal power stations by 2025, while the EU projects an 83% drop in coal-generated electricity by 2030, resulting in a significant decrease in fly ash supply. Like fly ash, slag, and silica fume, natural clays are also abundant sources of silica, alumina, and other essential chemicals for geopolymer binders. Hence, natural clays possess good potential to replace these industrial byproducts. Recent research indicates that locally available clay has strong potential as a pozzolanic material when treated appropriately. This review article represents a comprehensive overview of the various treatment methods for different types of clays, their impacts on the fresh and hardened properties of geopolymer concrete by analysing the experimental datasets, including 1:1 clays, such as Kaolin and Halloysite, and 2:1 clays, such as Illite, Bentonite, Palygorskite, and Sepiolite. Furthermore, this review article summarises the most recent geopolymer-based prediction models for strength properties and their accuracy in overcoming the expense and time required for laboratory-based tests. This review article shows that the inclusion of clay reduces concrete workability because it increases water demand. However, workability can be maintained by incorporating a superplasticiser. Calcination and mechanical grinding of clay significantly enhance its pozzolanic reactivity, thereby improving its mechanical performance. Current research indicates that replacing 20% of calcined Kaolin with fly ash increases compressive strength by up to 18%. Additionally, up to 20% replacement of calcined or mechanically activated clay improved the durability and microstructural performance. The prediction-based models, such as Artificial Neural Network (ANN), Multi Expression Programming (MEP), Extreme Gradient Boosting (XGB), and Bagging Regressor (BR), showed good accuracy in predicting the compressive strength, tensile strength and elastic modulus. The incorporation of clay in geopolymer concrete reduces reliance on industrial byproducts and fosters more sustainable production practices, thereby contributing to the development of a more sustainable built environment.