Search Results (13)

Geopolymer foam concrete (GFC) is a green, lightweight material produced by introducing bubbles into the geopolymer slurry. The raw materials for GFC are primarily silicon–aluminum-rich minerals or solid waste. Lead–zinc tailings (LZTs), as an industrial solid waste with high silicon–aluminum content, hold significant potential as raw materials for building materials. This study innovatively utilized LZTs to prepare GFC, incorporating MK, GGBS, and alkali activators as silicon–aluminum-rich supplementary materials and using H₂O₂ as a foaming agent, successfully producing GFC with excellent properties. The effects of different LZT content on the pore structure and various macroscopic properties of GFC were comprehensively evaluated. The results indicate that an appropriate addition of LZT effectively optimizes the pore structure, resulting in uniform pore distribution and pore shapes that are more spherical. Spherical pores exhibit better geometric compactness. The optimal LZT content was determined to be 40%, at which the GFC exhibits the best compressive strength, thermal conductivity, and water resistance. At this content, the dry density of GFC is 641.95 kg/m³, the compressive strength reaches 6.50 MPa after 28 days, and the thermal conductivity is 0.176 (W/(m·K)). XRD and SEM analyses indicate that under the combined effects of geopolymerization and hydration reactions, N–A–S–H gel and C–S–H gel were formed. The preparation of GFC using LZTs shows significant potential and research value. This study also provides a feasible scheme for the recycling and utilization of LZTs. Full article

The objective of this research is to fabricate waste-based alkali-activated foams with better properties in a quick time by using energy-efficient techniques such as microwave irradiation. The present study reports the effect of microwave heating parameters, including heating time and output power, on the properties of porous alkali-activated materials (AAMs) that use coal gangue (CG) as a precursor. The effects of concrete waste (CW) content (0–20 wt %) on the performance and microstructure of CG-based AAMs were investigated. Mechanical, thermal, and microstructural investigations were conducted to characterize the obtained materials. The experimental results indicate that the best characteristics of CG-based alkali-activated foams were achieved when microwave power and microwave heating time were 800 W and 10 min, respectively. The foams prepared by adding the waste concrete powder increased stability and showed lower bulk density and thermal conductivity. When the waste concrete powder content was 10 wt %, the CG-based alkali-activated foams showed the best overall performance. At the same time, the mechanical properties of the alkali-activated foams declined only slightly (~9%). The findings of this work provide a basis for further studies on improving the characteristics of CG-based alkali-activated foams due to the physical effect of a microwave field on fresh mortar without the use of a chemical foaming agent while reducing energy consumption in the production process. Full article

Geopolymers are binder materials that are produced by a chemical reaction between silica or aluminum compounds with an alkaline activating solution. Foamed geopolymer materials are increasingly being cited as a viable alternative to popular organic insulation materials. Since the foaming process of geopolymers is difficult to control, and any achievements in improving the performance of such materials are extremely beneficial, this paper presents the effect of the addition of basalt powder on the properties of foamed geopolymers. This paper presents the results of physicochemical studies of fly ash and basalt, as well as mechanical properties, thermal properties, and structure analysis of the finished foams. The scope of the tests included density tests, compressive strength tests, tests of the thermal conductivity coefficient using a plating apparatus, as well as microstructure tests through observations using light and scanning microscopy. Ground basalt was introduced in amounts ranging from 0 to 20% by mass. It was observed that the addition of basalt powder contributes to a reduction in and spheroidization of pores, which directly affect the density and pore morphology of the materials tested. The highest density of 357.3 kg/m³ was characterized by samples with a 5 wt.% basalt powder addition. Their density was 14% higher than the reference sample without basalt powder addition. Samples with 20 wt.% basalt addition had the lowest density, and the density averaged 307.4 kg/m³. Additionally, for the sample containing 5 wt.% basalt powder, the compressive strength exceeded 1.4 MPa, and the thermal conductivity coefficient was 0.1108 W/m × K. The effect of basalt powder in geopolymer foams can vary depending on many factors, such as its chemical composition, grain size, content, and physical properties. The addition of basalt above 10% causes a decrease in the significant properties of the geopolymer. Full article

This research used fly ash and slag to create geopolymer foam concrete. They were activated with an alkali, resulting in a chemical reaction that produced a gel that strengthened the concrete’s structural integrity. The experimental approach involved varying the fly ash content in the precursors at incremental percentages (10%, 30%, 50%, 70% and 90%) and subjecting the fly ash to mechanical activation through a planetary ball mill at distinct rotational speeds (380, 400, 420 and 440 rpm). The investigation discerned that the fly ash content and particle structure exert a discernible influence on macroscopic properties, including flowability, air generation height, compressive strength, dry density and microstructural characteristics such as pore distribution and hydration product arrangement in the geopolymer foam concrete. Employing analytical techniques such as X-ray diffraction (XRD) and scanning electron microscopy (SEM), it was deduced that diminishing the fly ash content correlates with an enhancement in compressive strength. Furthermore, the specific strength of the geopolymer foam concrete reached a peak of 0.041 when the activated fly ash in the planetary ball mill rotated at 420 rpm, manifesting a lightweight and high-strength outcome. Full article

Ash and slag waste (ASW) from coal combustion creates significant environmental and economic challenges. A promising method of ASW recycling is alkali activation with geopolymer material formation. This study investigates the influence of activating solution components (sodium hydroxide and sodium silicate) on the formation of porous geopolymers using ASW of different origins. The sodium hydroxide content of 0–4 wt.% and the sodium silicate content of 17–25 wt.% were studied. An increase in sodium hydroxide resulted in decreased density, but it adversely affected the strength. An increase in sodium silicate led to a compromised porous structure with relatively high density and compressive strength. An optimal composition, S19N3, comprising 3 wt.% of sodium hydroxide and 19 wt.% of sodium silicate obtained porous geopolymers with uniformly distributed 1.4–2 mm pores and a corresponding density of 335 kg/m³, a compressive strength of 0.55 MPa, a porosity value of 85.6%, and a thermal conductivity value of 0.075 W/(m·K). A mechanism for porous geopolymer formation was developed, including the interaction of alkaline components with ASW and a foaming agent, foaming, curing, and densification. The mechanism was examined using ASW from the Severodvinsk CHPP-1. This study allows for the optimization of geopolymer mixtures with various waste sources and the utilization of waste materials in the construction industry. Full article

Geopolymers can be used as a thermally insulated material because of their considerable porosity, whereas the combined effect of various modifying agents on their heat-insulating properties remains unexplored. Here, orthogonal experiments were carried out to evaluate the thermal insulation performance of fly ash geopolymer modified by phenolic resin, silica aerogel, and hydrogen peroxide. Moreover, variance analysis and range analysis were applied to estimate the influence of modifying agents on the thermal insulation performance of the geopolymer. The results demonstrate that the thermal conductivity of fly ash geopolymer significantly reduces (from 0.48 W/m·K to 0.12 W/m·K) due to the combined effect of the three modifying agents. Based on the variance analysis and range analysis, the optimum thermal conductivity ultimately reaches 0.08 W/m·K via a best composition scheme of the three modifying agents. Moreover, phenolic resin can facilitate the formation of a network structure and increase the porosity of micron pores (>1 μm). Hydrogen peroxide can be decomposed into O₂ in an alkaline environment and leave large-diameter pores (>1 μm) during curing. Some silica aerogel is embedded in the geopolymer matrix as microspheres with extremely low thermal conductivity, whereas the rest of the silica aerogel may react with the alkali activator to form water, and subsequently leaves pores (>1 μm) after evaporation of water during the curing. In addition, a newly modified Maxwell–Euchen model using iterative calculation and considering the Knudsen effect (pores of micron or even nanometer scale) is proposed and validated by the experimental data. The foamed geopolymer in this research can be used as a reference for building insulation layer design. This research unravels phenolic resin-, silica aerogel-, and hydrogen peroxide-influenced thermal insulation mechanisms of geopolymer that may have impacts on deployment of a thermally insulating material in the construction field. Full article

The regularities of obtaining foamed alkali-activated geopolymer materials based on different wastes of coal power engineering (fly ash, fuel (boiler) slag, ash, and slag mixture) were considered. The phase composition of the studied waste showed the presence of a significant amount of the amorphous phase, as well as a crystalline phase. mostly in the form of high quartz. The microstructure of studied the waste showed that the fly ash consisted of monodisperse hollow aluminosilicate microspheres, the fuel slag was represented by polydisperse irregular particles, and the ash and slag mixture included both of these materials in different ratios. Blowing agents such as aluminum powder, hydrogen peroxide, and sodium hypochlorite were chosen to achieve the porous structure of the geopolymer materials. The calculations of the geopolymer precursor compositions were carried out. Samples were synthesized, and their physical and mechanical properties, such as density, strength, porosity, and thermal conductivity, were analyzed. The micro- and macrostructure of the samples, as well as the pore distribution of the obtained geopolymers were studied. Conclusions were made on the choice of the most-optimal foaming agent and the optimal coal combustion waste suitable for the synthesis of the geopolymer materials. Full article

Approximately 45% of global greenhouse gas emissions are caused by the construction and use of buildings. Thermal insulation of buildings in the current context of climate change is a well-known strategy to improve the energy efficiency of buildings. The development of renewable insulation material can overcome the drawbacks of widely used insulation systems based on polystyrene or mineral wool. This study analyzes the sustainability and thermal conductivity of new insulation materials made of Miscanthus x giganteus fibers, foaming agents, and alkali-activated fly ash binder. Life cycle assessments (LCA) are necessary to perform benchmarking of environmental impacts of new formulations of geopolymer-based insulation materials. The global warming potential (GWP) of the product is primarily determined by the main binder component sodium silicate. Sodium silicate’s CO₂ emissions depend on local production, transportation, and energy consumption. The results, which have been published during recent years, vary in a wide range from 0.3 kg to 3.3 kg CO₂-eq. kg⁻¹. The overall GWP of the insulation system based on Miscanthus fibers, with properties according to current thermal insulation regulations, reaches up to 95% savings of CO₂ emissions compared to conventional systems. Carbon neutrality can be achieved through formulations containing raw materials with carbon dioxide emissions and renewable materials with negative GWP, thus balancing CO₂ emissions. Full article

Geopolymers represent a new class of inorganic materials that have great potential for practical application due to the properties of used raw materials, as well as the peculiarities of the cementitious matrix structure formed during the geopolymerization process. Cellular geopolymer specimens were produced in this study using class F fly ash product, which is characterized by low reactivity during geopolymerization. Several standard methods, as well as microstructural studies were applied to evaluate the effect of the following factors on the physical-mechanical and thermophysical characteristics of cellular geopolymers: the use of various mineral modifying components for synthesis of geopolymer systems; high-temperature treatment; the introduction method of alkaline activator. It was observed that “ageing” an aqueous alkali solution for 24 h before mixing with fly ash and foam agent was able to provide a boost of compressive strength of cellular geopolymer specimens up to about 2.5 times, while decreasing the average density by about 28% for all experimental mixes, except for PC-modified mixes. Additionally, high-temperature treatment at 600 °C enables an enhanced strengthening effect of pore structure in cellular geopolymer matrix up to 1.5 times. This phenomenon is especially pronounced for the mixes with 24 h “aged” alkaline solution with exception for PC-modified mixes; for those, high-temperature treatment at 600 °C leads to strength decrease up to 40%. The introduction method of alkaline activator and high-temperature treatment showed a controversial effect on thermal conductivity coefficient depending on the mineral modifying component used for the synthesis of cellular geopolymers. The proposed method for calculation of total porosity of cellular structure of geopolymers as a polycomponent material demonstrated a high degree of correlation with the R² value of at least 0.96 between the average density and the calculated total porosity. However, a low degree of correlation with R² not exceeding 0.29 was observed for the measured nanoporosity, regardless of the introduction method of alkaline activator and high-temperature treatment. Full article

This paper demonstrates the transformation of the industrial residue (copper slag) of a Swedish mining and smelting company “Boliden”, through geopolymerization, into advanced building materials. The main objective of this experimental study is the assessment of the appropriate conditions for the preparation of alkali-activated slag-based geopolymer pastes with further foaming production, by aluminum powder addition. The alkaline-activating solution used was KOH, at a constant concentration (8 M). The effect of crucial operating parameters, such as S/L ratio (3.5–4.5 g/mL) and aluminum powder addition (0.12%–0.22%), on the geopolymer paste were studied, in order to achieve the optimum rheological conditions of the slurry. The physical properties of the materials were examined after the appropriate curing process (24 h at 70 °C), with density values ranging between 805 and 1100 kg/m³. The mechanical performance of the materials ranged between 1.28 and 2 MPa (compressive strength), and from 0.25 to 0.85 MPa (flexural strength), indicating the strong correlation of physical and mechanical properties. To assess the porosity and the size distribution of the voids, image processing techniques were applied on digital images of selected samples. According to these results, the synthesized materials exhibit similar, or even better, properties than the current concrete porous materials. Full article

This work aims to investigate the feasibility that alkali-based geopolymer foams produced from metakaolin and Na₂O₂ are applied for fire protection. Dry bulk density, porosity, mechanical strength, thermal conductivity, and fire resistance of the geopolymer foams are discussed as a function of the Na₂O₂ amounts. As Na₂O₂ content varies from 1% to 4%, dry bulk density, mechanical strength and thermal conductivity of the geopolymer foams approximately exhibit opposite trends with that of the porosity. At the later stage of the 3 h fire-resistance tests, the reverse-side temperatures of all tested samples were always maintained at 220–250 °C. Meanwhile, the amorphous skeleton structures have been converted to smooth ceramics during the high temperature processes, which is the main reason that the geopolymer foams possess a stable porous structure and excellent fire resistance. Therefore, we could conclude that alkali-activated geopolymer foams with extraordinary fire resistance have great potential for fire protection applications. Full article

A ‘weak alkali activation’ was applied to aqueous suspensions based on soda lime glass and coal fly ash. Unlike in actual geopolymers, an extensive formation of zeolite-like gels was not expected, due to the low molarity of the alkali activator (NaOH) used. In any case, the suspension underwent gelation and presented a marked pseudoplastic behavior. A significant foaming could be achieved by air incorporation, in turn resulting from intensive mechanical stirring (with the help of a surfactant), before complete hardening. Dried foams were later subjected to heat treatment at 700–900 °C. The interactions between glass and fly ash, upon firing, determined the formation of new crystal phases, particularly nepheline (sodium alumino–silicate), with remarkable crushing strength (~6 MPa, with a porosity of about 70%). The fired materials, finally, demonstrated a successful stabilization of pollutants from fly ash and a low thermal conductivity that could be exploited for building applications. Full article

Ashes derived from the combustion of vegetal and animal biomass still represent a mostly unexplored secondary raw material for the production of alkali-activated materials, given their peculiar chemical nature. In this work, calcium phosphate biomass ashes were successfully used as partially reactive fillers in a metakaolin-based geopolymer composite to produce, by direct foaming, sustainable and lightweight boards with thermal insulating properties. The investigated materials were obtained by activating a blend of metakaolin and biomass ash in a weight ratio of 1: 1 and foamed with the addition of H₂O₂ in measure of 5 wt. %, to maximize the volume of disposed ash and ensure adequate properties to the material at the same time. The obtained geopolymer composite was characterized by microstructural, chemical-physical, mechanical and thermal analysis: the obtained results showed that biomass ash and metakaolin well integrated in the microstructure of the final porous material, which was characterized by a density of about 310 kg/m³ and a thermal conductivity of 0.073 W/mK at a mean test temperature of 30 °C, coupled with an acceptable compressive strength of about 0.6 MPa. Dilatometric and thermogravimetric analysis, performed up to 1000 °C, highlighted the thermal stability of the composite, which could be regarded as a promising material for low-cost, self-bearing thermal insulating partitions or lightweight cores for thermostructural sandwich panels. Full article