Search Results (124)

This study presents the fabrication and performance optimization of porous fly ash-based geopolymer (FAGP)–polyethersulfone (PES) composite fibers with tunable FAGP loading for the multivariate adsorption of heavy-metal ions from aqueous solutions. Fibers containing 20 wt%, 40 wt%, and 60 wt% FAGP were prepared using phase inversion method and were characterized using X-ray computed tomography and mechanical testing. Adsorption experiments were conducted to assess the removal efficiencies of Pb²⁺, Cd²⁺, Cu²⁺, and Ni²⁺ at different pH values, temperatures, contact times, adsorbent dosage and initial metal-ion concentrations. The composite containing 60 wt% FAGP exhibited the high performance for all ions, and its performance was especially high for Pb²⁺. The isotherm and kinetic modeling revealed that the adsorption process followed Freundlich and Redlich–Peterson models, with mixed chemisorption–physisorption mechanisms depending on the metal-ion type. Compared with conventional adsorbents, the optimized composite fibers exhibited high adsorption capacity, enhanced handling suitability, and scalability in addition to their sustainability owing to the use of industrial by-products as precursors. These findings provide new insights into the structure–function relationships of FAGP composite fiber adsorbents and their potential for wastewater treatment applications. Full article

The synergistic preparation of geopolymer from lithium slag, fly ash, and slag for underground construction can facilitate the extensive recycling of lithium slag. The effects of different activator moduli and water–binder ratios on the mechanical properties and damage mechanisms of the lithium-slag-based geopolymer were investigated by uniaxial compression tests and acoustic emission (AE) monitoring. The results show that, based on a comprehensive evaluation of peak stress, crack closure stress, plastic deformation stress, and elastic modulus, the optimal activator modulus is determined to be 1.0, and the optimal water-to-binder ratio is 0.42. At low modulus values (0.8 and 1.0) and low water–binder ratio (0.42), the AE events exhibit a steady pattern, indicating slow crack initiation and propagation within the geopolymer; with the increasing activator modulus and water-to-binder ratios, the frequency of AE events increases significantly, indicating more-frequent crack propagation and stress mutation within the geopolymer. Similarly, when the modulus is 0.8 or 1.0 and the water–binder ratio is 0.42, the sample presents a macroscopic tensile failure mode; as the modulus and water–binder ratio increase, the sample presents a tensile–shear composite failure mode. The energy evolution laws of geopolymer specimens with different activator moduli and water-to-binder ratios were analyzed, and a damage constitutive model was established. The results indicate that, with optimized mix proportions, the material can be used as a supporting material for underground spaces. Full article

Rapid population growth and accelerating urbanization are intensifying the demand for construction materials, particularly concrete, which is predominantly produced with Portland cement and natural aggregates. This reliance imposes substantial environmental burdens through resource depletion and greenhouse gas emissions. Within the framework of sustainable construction, recycled aggregates and industrial by-products such as fly ash, slags, crushed glass, and other secondary raw materials have emerged as viable substitutes in concrete production. At the same time, three-dimensional concrete printing (3DCP) offers opportunities to optimize material use and minimize waste, yet it requires tailored mix designs with controlled rheological and mechanical performance. This review synthesizes current knowledge on the use of recycled construction and demolition waste, industrial by-products, and geopolymers in concrete mixtures for 3D printing applications. Particular attention is given to pozzolanic activity, particle size effects, mechanical strength, rheology, thermal conductivity, and fire resistance of recycled-based composites. The environmental assessment is considered through life-cycle analysis (LCA), emphasizing carbon footprint reduction strategies enabled by recycled constituents and low-clinker formulations. The analysis demonstrates that recycled-based 3D printable concretes can maintain or enhance structural performance while mix-level (cradle-to-gate, A1–A3) LCAs of printable mixes report CO₂ reductions typically in the range of ~20–50% depending on clinker substitution and recycled constituents—with up to ~48% for fine recycled aggregates when accompanied by cement reduction and up to ~62% for mixes with recycled concrete powder, subject to preserved printability. This work highlights both opportunities and challenges, outlining pathways for advancing durable, energy-efficient, and environmentally responsible 3D-printed construction materials. Full article

The global construction industry faces growing pressure to minimize environmental impact while maintaining durable, high-performance building materials. Fly ash-based geopolymer concrete (GPC) provides a sustainable, low-carbon, durable, and high-performance alternative to ordinary Portland cement (OPC). However, challenges remain in accurately predicting its structural behavior, particularly flexural strength, under varying compositional and curing conditions. This study integrates a Blockchain-assisted Gene Expression Programming Framework (B-GEPF) to enhance reliability and traceability in durability assessments of fly ash-based GPC. Focusing on the silica modulus of alkaline activators, the framework aims to improve predictive accuracy for flexural strength and optimize durability performance. Flexural strength was evaluated under controlled alkaline activator conditions (8M sodium hydroxide with sodium silicate) and varying fine aggregate ratios (1:1.5, 1:2, 1:3). The predictive model captures complex nonlinear relationships among silica modulus, fly ash content, and flexural behavior. Results indicate that higher activator concentrations increase flexural strength, while fly ash improves workability, reduces heat of hydration, and sustains long-term strength through secondary reactions. The B-GEPF framework demonstrates potential to accelerate GPC formulation optimization, ensuring reproducibility, reliability, and industrial scalability. By combining AI-driven predictions with blockchain-based validation, this approach supports sustainable construction, quality assurance, regulatory compliance, and transparent stakeholder collaboration. The study highlights dual benefits of environmental sustainability and digital trust, positioning fly ash-based GPC as a durable, low-carbon, and verifiable solution for resilient infrastructure. This convergence of AI predictive modeling and blockchain-secured data governance offers a robust, scalable tool for designing, validating, and deploying eco-friendly construction materials. Full article

Today, several conventional wastes (fly ash, ground granulated blast furnace slags, etc.) are used as valid precursors for geopolymer synthesis. However, there are several new wastes that can be studied to replace geopolymer precursors. This study investigates the behavior of four industrial wastes—suction dust (SW1), red mud (SW2), electro-filter dust (SW3), and extraction sludge (SW4)—as 20 wt.% substitutes for metakaolin in geopolymer synthesis. The objective is to assess how their incorporation before alkali activation affects the structural, thermal, mechanical, chemical, and antimicrobial properties of the resulting geopolymers, namely GPSW1–4. FT-IR analysis confirmed successful geopolymerization in all samples (the main Si-O-T band underwent redshift, confirming Al incorporation in geopolymer structures after alkaline activation), and stability tests revealed that none of the GPSW1–4 samples disintegrated under thermal or water stress. However, GPSW3 showed an increase in efflorescence phenomena after these tests. Moreover, compressive strength was reduced across all waste-containing geopolymers (from 22.0 MPa for GP to 12.6 MPa for GPSW4 and values lower than 8.1 MPa for GPSW1–3), while leaching tests showed that GPSW1 and GPSW4 released antimony (127.5 and 0.128 ppm, respectively) above the legal limits for landfill disposal (0.07 ppm). Thermal analysis indicated that waste composition influenced dehydration and decomposition behavior. The antimicrobial activity of waste-based geopolymers was observed against E. coli, while E. faecalis showed stronger resistance. Overall, considering leaching properties, SW2 and SW3 were properly entrapped in the GP structure, but showed lower mechanical properties. However, their antimicrobial activity could be useful for surface coating applications. Regarding GPSW1 and GPSW4, the former needs some treatment before incorporation, since Sb is not stable, while the latter, showing a good compressive strength, higher thermal stability, and leaching Sb value not far from the legal limit, could be used for the inner reinforcement of building materials. Full article

Geopolymers are an environmentally sustainable class of low-calcium alkali-activated materials (AAMs), distinct from high-calcium C–A–S–H gel systems. Synthesized from aluminosilicate-rich precursors such as fly ash, metakaolin, slag, waste glass, and coal gasification fly ash (CGFA), geopolymers offer a significantly lower carbon footprint, valorize industrial by-products, and demonstrate superior durability in aggressive environments compared to Ordinary Portland Cement (OPC). Recent advances in thermodynamic modeling and phase chemistry, particularly in CaO–SiO₂–Al₂O₃ systems, are improving precursor selection and mix design optimization, while Artificial Neural Network (ANN) and hybrid ML-thermodynamic approaches show promise for predictive performance assessment. This review critically evaluates geopolymer chemistry and composition, emphasizing precursor reactivity, Si/Al and other molar ratios, activator chemistry, curing regimes, and reaction mechanisms in relation to microstructure and performance. Comparative insights into alkali aluminosilicate (AAS) and aluminosilicate phosphate (ASP) systems, supported by SEM and XRD evidence, are discussed alongside durability challenges, including alkali–silica reaction (ASR) and shrinkage. Emerging applications ranging from advanced pavements and offshore scour protection to slow-release fertilizers and biomedical implants are reviewed within the framework of the United Nations Sustainable Development Goals (SDGs). Identified knowledge gaps include standardization of mix design, LCA-based evaluation of novel precursors, and variability management. Aligning geopolymer technology with circular economy principles, this review consolidates recent progress to guide sustainable construction, waste valorization, and infrastructure resilience. Full article

High demand for sustainable solutions in the construction industry determines the significant relevance of developing new eco-friendly composites with a reduced carbon impact on the environment. The main aim of this study is to investigate the possibility and efficiency of using technical sulfur (TS) as a modifying additive for geopolymer composites and to select the optimal content of polypropylene fiber (PF). To assess the potential of TS, experimental samples of geopolymer solutions based on metakaolin and fly ash were prepared. The TS content varied from 0% to 9% by weight of binder in 3% increments. In the first stage, the density, compressive and flexural strength, capillary water absorption and microstructure of hardened geopolymer composites were tested. The TS additive in an amount of 3% was the most effective and provided an increase in compressive strength by 12.6%, flexural strength by 12.8% and a decrease in capillary water absorption by 18.2%. At the second stage, the optimal PF content was selected, which was 0.75%. The maximum increases in strength properties were recorded for the composition with 3% TS and 0.75% PF: 8% for compression and 32.6% for bending. Capillary water absorption decreased by 12.9%. The geopolymer composition developed in this work, modified with TP and PF, has sufficient mechanical and physical properties and can be considered for further study in order to determine its competitiveness with cement composites in real construction practice. Full article

The utilization of steel slag (SS) in construction materials represents an effective approach to improving its overall recycling efficiency. This study incorporates SS into a conventional ground granulated blast-furnace slag (GGBS)–fly ash (FA)-based binder system to develop a ternary system comprising SS, GGBS, and FA, and investigates how this system influences the static mechanical properties of ultra-high-performance geopolymer concrete (UHPGC). An axial point augmented simplex centroid design method was employed to systematically explore the influence and underlying mechanisms of different binder ratios on the workability, axial compressive strength, and flexural performance of UHPGC, and to determine the optimal compositional range. The results indicate that steel slag has a certain negative effect on the flowability of UHPGC paste; however, with an appropriate proportion of composite binder materials, the mixture can still exhibit satisfactory flowability. The compressive performance of UHPGC is primarily governed by the proportion of GGBS in the ternary binder system; an appropriate GGBS content can provide enhanced compressive strength and elastic modulus. UHPGC exhibits ductile behavior under flexural loading; however, replacing GGBS with SS significantly reduces its flexural strength and energy absorption capacity. The optimal static mechanical performance is achieved when the mass proportions of SS, GGBS, and FA are within the ranges of 9.3–13.8%, 66.2–70.7%, and 20.0–22.9%, respectively. This study provides a scientific approach for the valorization of SS through construction material applications and offers a theoretical and data-driven basis for the mix design of ultra-high-performance building materials derived from industrial solid wastes. Full article

The road construction sector urgently requires environmentally friendly, low-carbon, and high-performance base materials. Traditional materials exhibit issues of high energy consumption and carbon emissions, making it difficult for them to align with sustainable development requirements. While slag- and fly ash-based geopolymers demonstrate promising application potential in civil engineering, research on their application in road-stabilized soils remains insufficient. To address the high energy consumption and carbon emissions associated with conventional road base materials and to fill this research gap, this study investigated the utilization of industrial solid wastes through slag-based geopolymer and fly ash as stabilizers, systematically evaluating the pavement performance of two distinct soil types. Unconfined compressive strength tests and freeze–thaw cycling tests were conducted to elucidate the effects of stabilizer dosage, fly ash co-stabilization, and compaction degree on mechanical properties. The results demonstrated that the compressive strength of both stabilized soils increased significantly with higher slag-based geopolymer content, achieving peak values of 5.2 MPa (soil sample 1) and 4.5 MPa (soil sample 2), representing a 30% improvement over cement-stabilized soils with identical mix proportions. Fly ash co-stabilization exhibited more pronounced reinforcement effects on soil sample 2. At a 98% compaction degree, soil sample 1 maintained a stable 50% strength enhancement, whereas soil sample 2 displayed a dose-dependent exponential strength increase. Freeze–thaw resistance tests revealed the superior performance of soil sample 1, showing a loss of compressive strength (BDR) of 78% with 8% geopolymer stabilization alone, which improved to 90% after fly ash co-stabilization. For soil sample 2, the BDR increased from 64% to 80% through composite stabilization. This study confirms that slag/fly ash-based geopolymer-stabilized soils not only meet the strength requirements for heavy-traffic subbases and light-traffic base courses, but also demonstrates its great potential as a low-carbon and environmentally friendly material to replace traditional road base materials. Full article

This paper presents the results of testing the insulation performance of geopolymers based on fly ashes with the addition of waste broken glass. The waste glass was dried and ground to a maximum of 1 mm grain size. The proportions of broken glass in the total binder’s mass were 0%, 10%, 20%, and 30%. Sodium hydroxide and sodium silicate were the activators of the alkaline reaction. The obtained geopolymer materials were characterised by determining the basic physico-mechanical properties. The chemical composition, density, and thermal conductivity coefficient were determined. The mechanical performance, including compressive and flexural strength, was investigated after 28 days of curing. The morphological analysis was also carried out using microphotographs obtained from optical and scanning microscopes. A significant effect of the waste glass on the tested geopolymers’ mechanical performance was observed. Proportions of 10% and 20% broken glass in the binder led to more than a four-fold increase in the compressive strength and a two-fold increase in the flexural strength compared to the geopolymer without the waste glass. All tested geopolymers had excellent insulation ability compared to the reference mortar (more than 80% higher than cement mortar). However, the problem is potential alkali–silica reaction, which can occur when the waste glass content is high. Full article

Despite the availability of various materials for chimney applications, ongoing research seeks alternatives with improved thermal and chemical resistance. Geopolymers are a promising solution, exhibiting exceptional resistance to high temperatures, fire, and aggressive chemicals. This study investigates fly ash-based lightweight geopolymer concretes that incorporate expanded clay aggregate (E.C.A.), perlite (P), and foamed geopolymer aggregate (F.G.A.). The composites were designed to ensure a density below 1200 kg/m³, reducing overall weight while maintaining necessary performance. Aggregate content ranged from 60 to 75 wt.%. Physical (density, thickness, water absorption), mechanical (flexural and compressive strength), and thermal (conductivity, resistance) properties were evaluated. F.G.A. 60 achieved a 76.8% reduction in thermal conductivity (0.1708 vs. 0.7366 W/(m·K)) and a 140.4% increase in thermal resistance (0.1642 vs. 0.0683). The F.G.A./E.C.A./P 60 mixture showed the highest compressive strength (18.069 MPa), reaching 52.7% of the reference concrete’s strength, with a 32.3% lower density (1173.3 vs. 1735.0 kg/m³). Water absorption ranged from 4.9% (REF.) to 7.3% (F.G.A. 60). All samples, except F.G.A. 70 and F.G.A. 75, endured heating up to 800 °C. The F.G.A./E.C.A./P 60 composite demonstrated well-balanced performance: low thermal conductivity (0.2052 W/(m·K)), thermal resistance up to 1000 °C, flexural strength of 4.386 MPa, and compressive strength of 18.069 MPa. The results confirm that well-designed geopolymer lightweight concretes are suitable for chimney and flue pipe linings operating between 500 and 1000 °C and exposed to acidic condensates and aggressive chemicals. This study marks the initial phase of a broader project on geopolymer-based prefabricated chimney systems. 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

It has been proven that silica fume (SF), which is a by-product from the manufacturing of single-crystal silicon, is beneficial for enhancing the mechanical properties, durability, and workability of geopolymers, as it can be quickly dissolved and form silicate-based cementitious phases in alkaline environments. However, the reinforcement mechanism of SF on geopolymer remains unclear due to the chemical complexity of geopolymer and the variety of SF types. Additionally, the solubility of calcite in an alkali environment is quite limited, and thus the formation of the amorphous calcium-based gels will be thwarted due to the lack of soluble calcium ions. Most importantly, with the development of the single-crystal industry, the amorphous silica content, crystallinity, and trace elements of SF itself have changed, which blocks the understanding of the activation mechanism of geopolymers combined with SF and insoluble calcite. To unveil the underlying modification mechanisms of SF on geopolymer materials along with insoluble calcite, in this study, two types of SF were used as the fly ash replacement in a fly ash/limestone system to prepare geopolymer materials. The reinforcement effect significantly depends on the SF types even with similar particle size and chemical compositions. The results indicate that the mechanical properties of geopolymer materials modified with SFs are not only governed by the ratio and contents of Si, Ca, Al, and Mg in SFs but also depend on the crystallinity and activity of the SFs. The hydration products could be varied according to the reaction environment. The research results not only contribute to the optimization design and application of geopolymer materials but also pave new pathways for the upcycling use of solid wastes such as SF, low-grade fly ash, or even other aluminosilicate solid wastes to achieve sustainable development. Full article

Geopolymers possess good mechanical properties and durability, and their partial replacement of traditional Portland cement is noteworthy for promoting the development of low-carbon building materials. To clarify the influence mechanism of the mechanical properties of slag-fly ash-based geopolymer mortar, this paper investigated the hydration heat, composition, and morphology of hydration products with various contents and moduli of waterglass. The results showed that the compressive strength of geopolymer mortar increased with increasing waterglass content, and first rose and then fell as the waterglass modulus raised, while its flexural strength increased and then decreased with the growth in both. The compressive and flexural strength of geopolymer mortar with 1.2-modulus waterglass at 20 wt% cured for 28 days were 88.4 MPa and 9.0 MPa, respectively. The hydration temperature and cumulative hydration heat of geopolymer mortar was elevated with the increase in waterglass content, and declined with the rising waterglass modulus. The hydration products of the geopolymer consisted of dense amorphous and flocculent structures wrapped around each other. The microstructure of the geopolymer cured for 3 days was loose when the content of 1.4-modulus waterglass was 5 wt%. The relative areas of the flocculation in the geopolymer cured for 28 days increased while the waterglass modulus was greater than 1.4, forming an interface with the dense amorphous structure generated during the early hydration stage, leading to a decrease in its mechanical properties. Therefore, it is recommended for slag-fly ash geopolymer mortar that the waterglass modulus is between 1.2 and 1.4 and its content is no less than 10 wt% to ensure suitable mechanical properties. This study also provided a referenceable time period for the pouring and operation of the engineering application of slag-fly ash-based geopolymer repair mortar. Full article

The utilization of tannery sludge (TS) in construction materials not only effectively reduces pollution and resource consumption associated with waste disposal, but also promotes low carbon transformation in the building materials sector, further advancing sustainable development of green construction. This study aims to investigate the impact of sludge-based geopolymer gel on cementitious material performance, revealing the evolution mechanisms of material fluidity, setting time, hydration process, and compressive strength under the coupled effects of tannery sludge and alkali activation, thereby providing a reusable technical pathway to address the resource utilization challenges of similar special solid wastes. A series of alkali-activated composite cementitious materials (AACC) were prepared in the study by partially substituting cement with alkaline activators, TS, and fly ash (FA), through adjustments in TS–FA ratios and alkali equivalent (AE) variations. The workability, hydration process, and compressive strength evolution of AACC were systematically investigated. The experimental results indicated that as the TS content increased from 0% to 100%, the fluidity of fresh AACC decreased from 147 mm to 87 mm, while the initial and final setting times exhibited an exponential upward trend. The incorporation of TS was found to inhibit cement hydration, though this adverse effect could be mitigated by alkaline activation. Notably, 20–40% sludge dosages (SD) enhanced early-age compressive strength. Specifically, the compressive strength of the 0% TS group at 3 d age was 24.3 MPa, that of the 20% TS group was 25.9 MPa (an increase rate of 6.58%), and that of the 40% TS group was 24.5 MPa (an increase rate of 0.82%), whereas excessive additions resulted in the reduction of hydration products content and diminished later stage strength development. Furthermore, the investigation into AE effects revealed that maximum compressive strength (37.4 MPa) was achieved at 9% AE. These findings provide critical data support for realizing effective utilization of industrial solid wastes. Full article