Search Results (139)

This research evaluates the mechanical properties, environmental impacts, and cost-effectiveness of Hub Coal fly ash (FA)-based geopolymer concrete (FAGPC) as a sustainable alternative to ordinary Portland cement (OPC) concrete. This local FA has not been investigated previously. A total of 24 FAGPC mixes were tested under both ambient and heat curing conditions, varying the molarities of sodium hydroxide (NaOH) solution (10-M, 12-M 14-M and 16-M), sodium silicate to sodium hydroxide (Na₂SiO₃/NaOH) ratios (1.5, 2.0, and 2.5), and alkaline activator solution to fly ash (AAS/FA) ratios (0.5 and 0.6). The test results demonstrated that increasing NaOH molarity enhances the compressive strength (CS.) by 145% under ambient curing, with a peak CS. of 32.8 MPa at 16-M NaOH, and similarly, flexural strength (FS.) increases by 90% with a maximum FS. of 6.5 MPa at 14-M NaOH. Conversely, increasing the Na₂SiO₃/NaOH ratio to 2.5 reduced the CS. and FS. of ambient-cured specimens by 12.5% and 10.5%, respectively. Microstructural analysis revealed that higher NaOH molarity produced a denser, more homogeneous matrix, supported by increased Si–O–Al bond formation observed through energy-dispersive X-ray spectrometry. Environmentally, FAGPC demonstrated a 35–40% reduction in embodied CO₂ emissions compared to OPC, although the production costs of FAGPC were 30–35% higher, largely due to the expense of alkaline activators. These findings highlight the potential of FAGPC as a low-carbon alternative to OPC concrete, balancing enhanced mechanical performance with sustainability. New, green, and cheap activation solutions are sought for a new generation of more sustainable and affordable FAGPC. Full article

Additive manufacturing has recently become popular and more cost-effective for building construction. This study presents a prospective life cycle assessment (LCA) of 3D-printed foamed geopolymer composites (3D-FOAM materials) incorporating construction and demolition waste. The materials were developed using fly ash, slag, sand, and a foaming agent, with recycled clay brick waste (CBW) and autoclaved aerated concrete waste (AACW) added as alternative raw materials. The material formulations were evaluated for their compressive strength and thermal conductivity to define two functional units that reflect structural and thermal performance. A prospective life cycle assessment (LCA) was conducted under laboratory-scale conditions using the ReCiPe 2016 method. Results show that adding CBW and AACW reduces environmental impacts across several categories, including global warming potential and ecotoxicity, without compromising material performance. Compared to conventional wall systems, the 3D-FOAM materials offer a viable low-impact alternative when assessed on a functional basis. These findings highlight the potential of integrating recycled materials into additive manufacturing to support circular economy goals in the construction sector. Full article

Using innovative and sustainable materials has become crucial for developed countries. Reusing waste as a secondary raw material in industrial processes central to the circular economy could enhance environmental sustainability and support local economies. Building materials such as Portland cement have a significant environmental impact due to greenhouse gas emissions and construction and demolition waste (CDW), which is challenging to recycle. Research into sustainable alternatives is, therefore, essential. The European Union has set ambitious targets to reduce greenhouse gas emissions by 55% by 2030 and achieve climate neutrality by 2050. The National Recovery and Resilience Plan (PNRR) supports the green transition in Italy by promoting sustainable materials like geopolymers. These ceramic-like materials are based on aluminosilicates obtained through the chemical activation of waste rich in silica and aluminosilicate compounds. Though promising, these materials require further research to address challenges like long-term durability and chemical variability. Collaboration between scientific research and industry is essential to develop specific protocols and suitable infrastructures. This article provides a critical review of the advancements and challenges in using alkali-activated waste as construction binders, focusing on Italy, and encourages the exploration of alternative sustainable materials beyond conventional Portland cement. Full article

Geopolymers (GPs), as promising alternatives to ordinary Portland cement (OPC)-based concrete, have gained interest in the last 20 years due to their enhanced mechanical properties, durability, and lower environmental impact. Synthesized from industrial by-products such as slag and fly ash, geopolymers offer a sustainable solution to waste management, resource utilization, and carbon dioxide reduction. However, similarly to OPC, geopolymers exhibit brittle behavior, and this characteristic defines a limit for structural applications. To tackle this issue, researchers have focused on the characterization, development, and implementation of fiber-reinforced geopolymers (FRGs), which incorporate various fibers to enhance toughness, ductility, and crack resistance, allowing their use in a wide range of structural applications. Following a general overview of sustainability considerations, this review critically analyzes the structural performance and capability of geopolymers in structural repair applications. Geopolymers demonstrate notable potential in new construction and repair applications. However, challenges such as complex mix designs, the availability of alkaline activators, curing temperatures, fiber matrix compatibility issues, and limited standards are restricting its large-scale adoption. The analysis and consolidation of an extensive dataset would support the viability of geopolymer as a durable and sustainable alternative to what is currently used in the construction industry, especially when fiber reinforcement is effectively integrated. Full article

Rubberized concrete is a more environmentally friendly material than natural concrete as it helps to reduce rubber disposal issues and has superior impact resistance. Geopolymer concrete, on the other hand, is an economical concrete with higher mechanical properties than nominal concrete that uses fly ash and slag, among other industrial solid wastes, to lower carbon footprints. Rubberized geopolymer concrete (RuGPC) combines the advantages of both concrete types, and a thorough grasp of its dynamic compressive characteristics is necessary for its use in components linked to impact resistance. Despite the advantages of RuGPC, predicting its mechanical characteristics is sometimes difficult because of variations in binder type and combination. This research investigated the combined effect of ground granulated blast furnace slag (GGBFS) and fly ash (FA) on the workability, compressive strength, and stress–strain characteristics of RuGPC with rubber at 0%, 10%, and 20% fine aggregate replacement. Thereafter, energy absorption and ductile characteristics were evaluated through the concrete toughness and ductility index. Numerical models were proposed for the cube compressive strength, modulus of elasticity, and peak strain of RuGPC at different percentages of crumb rubber. It was found that RuGPC made with GGBFS/FA had similar stress–strain characteristics to FA- and MK-based RuGPC. At 20% of crumb rubber aggregate replacement, the workability, compressive strength, modulus of elasticity, and peak stress of RuGPC reduced by 8.33%, 34.67%, 43.42%, and 44.97%, while Poisson’s ratio, peak, and ultimate strain increased by 30.34%, 8.56%, and 55.84%, respectively. The concrete toughness and ductility index increased by 22.4% and 156.67%. The proposed model’s calculated results, with R² values of 0.9508, 0.9935, and 0.9762, show high consistency with the experimental data. RuGPC demonstrates high energy absorption capacity, making it a suitable construction material for structures requiring high-impact resistance. Full article

The construction industry generates large amounts of waste and high CO₂ emissions, especially from cement production. Sustainable alternatives, such as geopolymers, help reduce these impacts by promoting eco-friendly materials. This study aimed to develop geopolymer mortar using ignimbrite (IG) residues from the Arequipa region, Peru, combined with metakaolin (MK). The raw materials were characterized by X-ray diffraction (XRD), X-ray fluorescence (XRF), Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS) to assess the chemical composition, structure, and morphology. Geopolymeric mortars were synthesized with varying MK/IG ratios while maintaining a fixed fine sand proportion. An activating solution of 9 mol/L NaOH was used with different liquid-to-solid ratios. Geopolymers cured at room temperature for 28 days exhibited lower compressive strength than those dried at 50 °C for 48 h or sequentially at 50 °C for 48 h followed by 90 °C for 12 h. The highest IG-content mixture achieved a compressive strength of 18 MPa, while the MK-based geopolymer reached 12 MPa, both under high-temperature curing. An increase in the SiO₂/Al₂O₃ molar ratio was also associated with improved mechanical performance, reinforcing the influence of precursor composition on geopolymerization. These results highlight the potential of regional ignimbrite for the production of geopolymer mortar, promoting sustainable and innovative building materials. Full article

Renewable energy sources are presented as a key solution to today’s energy needs, but they also generate waste that can have a negative impact on the environment. In particular, fly ash from the incineration of municipal solid waste (MSW), classified as hazardous by European regulations, is often deposited in landfills due to its lack of usefulness. This research proposes its valorisation in geopolymers, combining it with mining to create a sustainable material with a high industrial waste content. Firstly, all the wastes involved were characterised, which allowed for the development of a high-quality geopolymer from mining residue activated with 5% NaOH. This material was enriched with up to 50% fly ash (in increasing percentages) with the aim of making it inert, retaining it in the geopolymer matrix, and observing its effect on the final material. The physical and mechanical properties of the geopolymers obtained were evaluated, demonstrating that they do not produce contaminating leachates. The results indicate the feasibility of developing a geopolymer with up to 20% fly ash, obtaining a building material comparable to traditional ceramics, suitable for commercialisation, with a lower environmental impact and in line with the principles of the circular economy. Full article

The construction industry urgently requires sustainable alternatives to conventional concrete to reduce its environmental impact. This study addresses this challenge by developing machine learning-optimized geopolymer concrete (GPC) using industrial waste fly ash as cement replacement. An integrated Taguchi–Grey relational analysis (GRA) and artificial neural network (ANN) approach was developed to simultaneously optimize mechanical properties and environmental performance. The methodology analyzes over 1000 data points from 83 studies to identify key mix parameters including fly ash content, NaOH/Na₂SiO₃ ratio, and curing conditions. Results indicate that the optimized FA-GPC formulation achieves a 78% reduction in CO₂ emissions, decreasing from 252.09 kg/m³ (GRC rank 1) to 55.0 kg/m³, while maintaining a compressive strength of 90.9 MPa. The ANN model demonstrates strong predictive capability, with R² > 0.95 for strength and environmental impact. Life cycle assessment reveals potential savings of 3941 tons of CO₂ over 20 years for projects using 1000 m³ annually. This research provides a data-driven framework for sustainable concrete design, offering practical mix design guidelines and demonstrating the viability of fly ash-based GPC as high-performance, low-carbon construction material. Full article

This research aims to develop self-healing geopolymer concrete (SHG) to address the limitations of conventional repair methods, including reduced thermal conductivity and density, while promoting sustainable construction. The incorporation of the self-healing method (SHM), crushed brick (CB), and minced water bottles (F-PET) resulted in reduced thermal conductivity, maintenance costs, and environmental impact. This study investigated the effects of varying amounts of CB, F-PET, and SHM on several properties, including flowability, setting times, densities, ductility index (DI), and mechanical strengths, across 13 different mixtures. Additionally, water absorption (WA%), residual weight loss (WL%), and relative dynamic modulus of elasticity (RDME%) were assessed following freeze–thaw cycles, alongside SEM analysis and thermal transport measurements of the SHG mixtures. The inclusion of up to 50% CB enhanced density and thermal conductivity but negatively affected other properties. In contrast, incorporating 25% F-PET led to modest improvements in mechanical, thermal, and durability properties; however, it did not reduce density and thermal conductivity as effectively as CB. Among the three mixtures containing both CB and F-PET, the formulation with 37.5% CB and 12.5% F-PET exhibited the lowest density (1650 kg/m³) and thermal conductivity (1.083 W/m·K). The self-healing capacity of SHM was demonstrated through its ability to close cracks, facilitated by the deposition of CaCO₃ under combined durability conditions. Incorporating 2%, 3%, and 4% SHM into the 37.5% CB and 12.5% F-PET mixture significantly improved key properties, including strength, water absorption, freeze–thaw resistance, SEM characteristics, density, and thermal conductivity. The addition of 4% SHM enhanced the mechanical performance of the geopolymer concrete (GVC) after 28 days, resulting in increases of 27% in compressive strength, 40.5% in tensile strength, 81% in flexural strength, and 61.6% in ductility index. Further, the inclusion of SHM improved density, reduced WA% and WL%, and enhanced RDME% after 300 freeze–thaw cycles. Specifically, thermal conductivity decreased from 1.8 W/m·K to 0.88 W/m·K, and density reduced from 2480 kg/m³ to 1760 kg/m³. Meanwhile, WA%, WL%, and RDME% improved from 3%, 4.5%, and 45% to 2%, 2.5%, and 50%, respectively. Full article

Geopolymer composite materials are a viable alternative to conventional construction materials. The research problem of geopolymer composites revolves around the imperative to comprehensively address their synthesis, structural performance, and environmental impact. The derived mathematical model facilitates precisely determining the optimal proportions of two crucial constituents in the geopolymer matrix: silica sand and secondary aluminum by-product. A mathematical model for optimizing the composition of geopolymer composites has been developed based on the integrated use of Markov chains, criterion methods, and an orthogonally compositional plan. The optimal composition of the geopolymer matrix is determined and predicted using a mathematical model. Specifically, the recommended content mixing ratio is as follows: metakaolin at 1000 g, activator at 900 g, silica fume at 1052.826 g, carbon fibre at 10 g, and secondary aluminum by-product at 62.493 g. This study analyzes the influence of different secondary aluminum industry by-products on the geopolymerization process and assesses the mechanical, thermal, and environmental properties of the resulting composites to establish a comprehensive understanding of their structural viability. Full article

Additive manufacturing has been of considerable interest for the last 10 years. Cementitious composites have been developed to ensure fast and effective structure printing. To address sustainability and reduce the environmental impact of Portland cement-based composites, geopolymer composites have been developed that can be printed. This brings us to this study’s aim, which is to allow the printing of recycled lightweight structures with not only the ability to act as a structural material but also insulation capabilities. This study focuses on mix design development and the mechanical strength, creep, and shrinkage properties of these composites. The results show that foamed 3D-printed fly ash-based geopolymer composites may have reduced compressive strength, but still have sufficient strength to be used as a structural material. Furthermore, their creep and shrinkage strain are lower than those of the composite without foaming agent introduction. Full article

Cement is widely used as the primary binder in concrete; however, growing environmental concerns and the rapid expansion of the construction industry have highlighted the need for more sustainable alternatives. Geopolymers have emerged as promising eco-friendly binders due to their lower carbon footprint and potential to utilize industrial byproducts. Geopolymer mortar, like other cementitious substances, exhibits brittleness and tensile weakness. Basalt fibers serve as fracture-bridging reinforcements, enhancing flexural and tensile strength by redistributing loads and postponing crack growth. Basalt fibers enhance the energy absorption capacity of the mortar, rendering it less susceptible to abrupt collapse. Basalt fibers have thermal stability up to about 800–1000 °C, rendering them appropriate for geopolymer mortars designed for fire-resistant or high-temperature applications. They assist in preserving structural integrity during heat exposure. Fibers mitigate early-age microcracks resulting from shrinkage, drying, or heat gradients. This results in a more compact and resilient microstructure. Using basalt fibers improves surface abrasion and impact resistance, which is advantageous for industrial flooring or infrastructure applications. Basalt fibers originate from natural volcanic rock, are non-toxic, and possess a minimal ecological imprint, consistent with the sustainability objectives of geopolymer applications. This study investigates the mechanical and thermal performance of a geopolymer mortar composed of metakaolin and red mud as binders, with basalt powder and limestone powder replacing traditional sand. The primary objective was to evaluate the effect of basalt fiber incorporation at varying contents (0.4%, 0.8%, and 1.2% by weight) on the durability and strength of the mortar. Eight different mortar mixes were activated using sodium hydroxide (NaOH) and sodium silicate (Na₂SiO₃) solutions. Mechanical properties, including compressive strength, flexural strength, and ultrasonic pulse velocity (UPV), were tested 7 and 28 days before and after exposure to elevated temperatures (200, 400, 600, and 800 °C). The results indicated that basalt fiber significantly enhanced the performance of the geopolymer mortar, particularly at a content of 1.2%. Specimens with 1.2% fiber showed up to 20% improvement in compressive strength and 40% in flexural strength after thermal exposure, attributed to the fiber’s role in microcrack bridging and structural densification. Subsequent research should concentrate on refining fiber type, dose, and dispersion techniques to improve mechanical performance and durability. Examinations of microstructural behavior, long-term durability under environmental settings, and performance following high-temperature exposure are crucial. Furthermore, investigations into hybrid fiber systems, extensive structural applications, and life-cycle evaluations will inform the practical and sustainable implementation in the buildings. Full article

Coal gangue (CG), a major solid waste generated during coal development, presents critical environmental challenges due to its large-scale accumulation and associated ecological impacts, thereby necessitating the development of efficient utilization strategies. This investigation developed a composite geopolymer system through the alkali-activated co-utilization of uncalcined CG and blast furnace slag (BFS), demonstrating an environmentally sustainable approach for industrial byproduct value addition. The effects of key parameters, including BFS content, liquid-to-solid ratio, alkali activator dosage, waterglass modulus, and curing regime, on the strength development were first investigated through single-factor experiments. Based on these results, response surface methodology was applied to optimize the preparation parameters and develop a quadratic regression model describing the relationship between compressive strength and the influencing factors. The optimal conditions (a waterglass modulus of 1.06, an alkali activator dosage of 13.81%, and an initial 24 h curing temperature of 30 °C) were determined to maximize compressive strength. The reaction mechanisms were further explored using XRD and SEM-EDS, which confirmed the existence of calcium silicate hydrate, calcium aluminum silicate hydrate, and geopolymer gel in the composite geopolymer matrix. Full article

Due to their low environmental impact, various mineral or cellulose-based natural fibres have recently attracted attention in the construction industry. Hence, the current study focused on basalt fibres and explored the changes in the physical, mechanical, and micro-structural properties of geopolymer concrete reinforced with such fibres. The current study used self-compacting geopolymer concrete, an eco-friendly concrete composed of fly ash, ground granulated blast furnace slag, and an alkali activator, in addition to the regular components of normal concrete. The self-compacting geopolymer concrete compacts under its own weight, so extra compaction is not required. The present study investigated the effect of the fibre content and length. Two different fibre lengths were considered: 12 mm and 30 mm. Three different percentages (1%, 2%, and 3% of the weight of the total mix) of the basalt fibres were considered to determine the optimum fibre content. The mix design was carried out for all the mixes with different fibre contents and fibre lengths, and the workability properties in the slump flow, T-500, and J-ring tests are presented. The effects of the fibre length and content were evaluated in terms of compressive strength (28 and 56 days) and split tensile strength. The results indicated that a higher fibre content effectively increased the compressive strength of 12 mm long fibres. In contrast, a lower fibre content was ideal for the 30 mm long fibres. In addition, the short fibres were more effective in enhancing the geopolymer concrete’s tensile strength than the long fibres. Furthermore, a detailed microscopic analysis was carried out, which revealed that fibre clustering, voids, etc., changed the strength of the selected fibre-reinforced self-compacting geopolymer concrete. Moreover, the analytical method’s predicted tensile strength agreed with the experimental results. Full article

The objective of this study was to explore the potential of creating advanced insulating biocomposites using waste almond and hazelnut shells as particulate fillers, combined with a geopolymer binder, to develop sustainable materials with minimal environmental impact. Optimal conditions for the preparation of biocomposites were determined by measuring the compressive strengths. The aforementioned optimal conditions included a geopolymer to waste nutshell mass ratio of 2, room-temperature curing, and the use of metakaolin geopolymers activated with potassium solutions. Notably, the highest compressive strengths of 4.1 MPa for hazelnut shells biocomposite and 6.4 MPa for almond shells biocomposite were obtained with milk of lime pretreatment at 80 °C for 1 h. Scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM/EDX) and Fourier transform infrared spectroscopy (FTIR) analyses revealed better adhesion, as well as improved geopolymer gel polymerization. Furthermore, thermal conductivity and diffusivity measurements demonstrated values characteristic of insulating materials, reinforcing their potential for eco-friendly construction applications. Full article