Search Results (17)

Silica fume-based geopolymer composite coatings, an approach to using metallurgical solid waste, exert flame retardancy with ecological, halogen-free, and environmentally friendly advantages, but their fire resistance needs to be improved further. Herein, a silica fume-based geopolymer composite flame-retardant coating was designed by doping boric acid (BA), zinc phytate (ZnPA), and melamine (MEL). The results of a cone calorimeter demonstrated that appropriate ZnPA and BA significantly enhanced its flame retardancy, evidenced by the peak heat release rate (p-HRR) decreasing from 268.78 to 118.72 kW·m⁻², the fire performance index (FPI) increasing from 0.59 to 2.83 s·m²·kW⁻¹, and the flame retardancy index increasing from 1.00 to 8.48, respectively. Meanwhile, the in situ-formed boron phosphate (BPO₄) facilitated the residual resilience of the fire-barrier layer. Furthermore, the pyrolysis kinetics indicated that the three-level chemical reactions governed the pyrolysis of the coatings. BPO₄ made the pyrolysis E_α climb from 94.28 (P5) to 127.08 (B3) kJ·mol⁻¹ with temperatures of 731–940 °C, corresponding to improved thermal stability. Consequently, this study explored the synergistic flame-retardant mechanism of silica fume-based geopolymer coatings doped with ZnPA, BA, and MEL, providing an efficient strategy for the high-value-added recycling utilization of silica fume. Full article

Geopolymers have emerged as promising materials for their superior thermal and mechanical properties, offering sustainable alternatives to conventional coatings. This study investigates the potential of Palm Oil Fuel Ash (POFA) as a raw material for fire-resistant geopolymer coatings. Through the optimization of POFA-to-alkaline activator (AA) ratios, NaOH concentrations, and curing temperatures, POFA-based coatings were synthesized and applied to mild steel substrates. Fire resistance testing revealed that the optimal formulation (0.35 POFA ratio, 8 M NaOH concentration, and curing at 65 °C) achieved a temperature at equilibrium (TAE) of 151.2 °C, significantly outperforming other compositions by reducing heat transfer during fire exposure. Thermal imaging and SEM analysis demonstrated that the optimized coating (GP-POFA8) exhibited a more uniform and stable intumescent layer, leading to lower peak temperatures (909 °C) compared to less optimized samples. Thermogravimetric Analysis (TGA) further confirmed that GP-POFA8 retained approximately 80% of its original mass at temperatures beyond 600 °C, highlighting its superior thermal stability. These findings underscore the potential of POFA-based geopolymers as effective, eco-friendly solutions for fire-resistant applications in construction and industrial sectors, contributing to sustainable waste management. Full article

The development of new composite materials with specific properties and reduced environmental pollution can be achieved by the incorporation of agricultural residues, whose morphology is strongly affected by their variety and growing conditions. Herein, the functional properties of a cement-free geopolymer composite reinforced with straw from two wheat varieties (Ada and Malibu) were investigated through different straw pre-treatment methods and their surface modification with silane coupling agents. The characterization of the wheat surface and the geopolymer composites involved SEM-EDS, TGA, FTIR, and gas physisorption analysis methods supplemented with mechanical strength and moisture ingress measurements. Mild (23 °C) and severe (100 °C) physical pre-treatment methods with chemical soaking in 7.3 M isopropanol solution were applied on wheat straw. Tetraethoxysilane (TEOS) with octadecylamine was employed for chemical surface modification. The set of geopolymer compositions was prepared with untreated, pre-treated, and modified straws. The results revealed the hot pre-treatment method caused a higher degradation of siliceous layers of straw, especially in the Ada variety. The modification with TEOS resulted in irregular silane coating formation regardless of the wheat variety and pre-treatment method. Despite good interfacial bonding of the modified straw with the geopolymer matrix, the mechanical strength of the composites was reduced, although the resistance to water ingress slightly increased. Comparing both varieties, Ada wheat showed better performance than Malibu. Full article

Shrinkage during hardening and curing is one of the largest challenges for the widespread application of metakaolin-based geopolymers (MKGs). To solve this problem, a silane coupling agent (SCA) and waterborne epoxy resin (WER) were used to synthesize MKG composites. The individual and synergistic effects of the SCA and WER on chemical, autogenous, and drying shrinkage were assessed, the modification mechanisms were investigated by microstructural characterization, and shrinkage resistance was evaluated by the chloride ion permeability of MKG composite coatings. The results showed that the SCA and WER significantly decreased the chemical shrinkage, autogenous shrinkage, and drying shrinkage of the MKG, with the highest reductions of 46.4%, 131.2%, and 25.2% obtained by the combination of 20 wt% WER and 1 wt% SCA. The incorporation of the organic modifiers densified the microstructure. Compared with the MKG, the total volume of mesopores and macropores in MKG-WER, MKG-SCA, and MKG-WER-SCA decreased by 11.5%, 8.7%, and 3.8%, respectively. In particular, the silanol hydrolyzed from the SCA can react with the opened epoxy ring of the WER and the aluminosilicate oligomers simultaneously to form a compact network and resist shrinkage during the hardening and continuous reaction of the geopolymer. Furthermore, the apparently lowered chloride ion diffusion coefficient of concrete (i.e., reduction of 51.4% to 59.5%) by the WER- and SCA-modified MKG coatings verified their improved shrinkage resistance. The findings in this study provide promising methods to essentially solve the shrinkage problem of MKGs at the microscale and shed light on the modification mechanism by WERs and SCAs, and they also suggest the applicability of MKG composites in protective coatings for marine concrete. Full article

The article discusses the fabrication of sandwich steel and geopolymer structures using spray technology without the need for formwork. In the article, the effects of high temperatures on geopolymer materials are analyzed and their mechanical properties and durability are examined. The importance of geopolymer coatings for steel protection is also highlighted, and specific features such as the setting time, application process, attachment strength, fire testing, and production costs are analyzed. The materials and methods used in the study are described, including the composition of geopolymer binders and the process of applying geopolymer coatings to steel plates. The research includes test methods such as strength tests, density tests, thermal conductivity tests, accelerated aging tests, microstructure analyses, pore size analyses, and fire resistance tests. The research section concludes with a summary of the chemical and phase composition of the materials and a discussion of the fire resistance of the geopolymer composites (GCs). The results show that GC foams offer excellent thermal insulation, providing up to 75 min of fire resistance with a 6 mm coating, reducing temperatures by 150 °C compared to uncoated steel. GC foams have a density of 670 kg/m³, a thermal conductivity of 0.153 W/m∙K, and a cost effectiveness of USD 250 per cubic meter. Full article

Various types of coatings are applied to the surface of an object or substrate to improve surface properties or extend service life, which in turn is associated with cost reductions. The main objective of this study was to develop a technique for the additive application of foamed geopolymers to existing structures and vertical surfaces. The base material was a fly ash-based geopolymer modified with sand. Hydrogen peroxide and aluminum powder were used as foaming agents. In this study, the feasibility of using an air gun with variable nozzles to apply the layers of foamed geopolymers was assessed, and the effects of nozzle diameter and the spray gun’s operating pressure were analyzed. The next stage of the study was a visual assessment of the layering of the foamed material. The foamed geopolymer layering tests verified the occurrence of the foaming process, and the applied geopolymer surface showed a reasonably good adhesive bond with the vertical wall. In addition, in this paper, we present the laser particle size results of the base materials and their oxide composition. In addition, thermal conductivity tests for the foamed geopolymer materials, compressive strength tests, and microstructure analysis via scanning electron microscopy were carried out. Full article

In the last decades, new synthetic hybrid materials, with an inorganic and organic nature, have been developed to promote their application as protective coatings and/or structural consolidants for several substrates in the construction industry and cultural heritage field. In this context, the scientific community paid attention to geopolymers and their new hybrid functional derivatives to design and develop innovative and sustainable composites with better chemical resistance, durability and mechanical characteristics. This review offers an overview of the latest progress in geopolymer-based hybrid nanofunctional materials and their use to treat and restore cultural heritage, as well as their employment in the building and architectural engineering field. In addition, it discusses the influence of some parameters, such as the chemical and physical characteristics of the substrates, the dosage of the alkaline activator, and the curing treatment, which affect their synthesis and performance. Full article

Nowadays, concepts of self-cleaning have received great attention in construction building materials. Self-cleaning with the presence of photocatalyst has been applied in building materials to overcome the problem of building surfaces becoming dirty after exposure for a long time in highly polluted areas. To date, the concept of green blending materials has led to the development of a new binding material for green materials, which is geopolymer with an addition of photocatalyst. This review focused on the development of conventional self-cleaning paste, including the method of preparation and the impact of adding photocatalyst on physical and mechanical properties. However, although self-cleaning has been widely applied in conventional cement paste, its applications in geopolymers are still in the early stages of development and require more research. Therefore, this paper also intended to review the current knowledge on properties of geopolymer cement-based composite and its potential to be applied as a self-cleaning coating. Full article

Geopolymer using aluminosilicate sources, such as fly ash, metakaolin and blast furnace slag, possessed excellent fire-retardant properties. However, research on the fire-retardant properties and thermal properties of geopolymer coating using rice husk ash (RHA) is rather limited. Additionally, the approach adopted in past studies on geopolymer coating was the less efficient one-factor-at-a-time (OFAT). A better approach is to employ statistical analysis and a regression coefficient model (mathematical model) in understanding the optimum value and significant effect of factors on fire-retardant and thermal properties of the geopolymer coating. This study aims to elucidate the significance of rice husk ash/activated alkaline solution (RHA/AA) ratio and NaOH concentration on the fire-retardant and thermal properties of RHA-based geopolymer coating, determine the optimum composition and examine the microstructure and element characteristics of the RHA-based geopolymer coating. The factors chosen for this study were the RHA/AA ratio and the NaOH concentration. Rice husk was burnt at a temperature of approximately 600 °C for 24 h to produce RHA. The response surface methodology (RSM) was used to design the experiments and conduct the analyses. Fire-retardant tests and thermal and element characteristics analysis (TGA, XRD, DSC and CTE) were conducted. The microstructure of the geopolymer samples was investigated by using a scanning electron microscope (SEM). The results showed that the RHA/AA ratio had the strongest effect on the temperature at equilibrium (TAE) and time taken to reach 300 °C (TT300). For the optimization process using RSM, the optimum value for TAE and TT300 could be attained when the RHA/AA ratio and NaOH concentration were 0.30 and 6 M, respectively. SEM micrographs of good fire-resistance properties showed a glassy appearance, and the surface coating changed into a dense geopolymer gel covered with thin needles when fired. It showed high insulating capacity and low thermal expansion; it had minimal mismatch with the substrate, and the coating had no evidence of crack formation and had a low dehydration rate. Using RHA as an aluminosilicate source has proven to be a promising alternative. Using it as coating materials can potentially improve fire safety in the construction of residential and commercial buildings. Full article

Geopolymer coating using rice husk ash (RHA) as the aluminosilicate source has shown excellent fire retardant properties. However, incorporation of rice husk ash into the geopolymer matrix increased water absorption properties of the polymer composite. As such, silicone rubber (SiR) was introduced to improve the moisture absorption and fire retardant properties of the composite. Additionally, the less efficient one-factor-at-a-time (OFAT) approach was conventionally used in past studies on the RHA-based geopolymer composite. In understanding the optimum value and significant effect of factors on the fire retardant and moisture absorption properties of the binary blended geopolymer coating composite, the use of statistical analysis and regression coefficient model (mathematical model) was considered essential. The objectives of this study are to identify the significant effect of factors on moisture absorption and fire retardant properties, to determine the optimum composition, and to study the microstructure of the rice husk ash/silicone rubber (RHA/SiR)-based binary blended geopolymer coating composite. The RHA/AA and SiR/Ge ratios were chosen as factors, and the response surface methodology (RSM) was employed to design experiments and conduct analyses. Fire retardant and moisture absorption tests were conducted. A scanning electron microscope (SEM) was used to observe the microstructure of geopolymer samples. The RHA/alkaline activator (AA) and SiR/Ge ratios were shown to have a significant effect on the responses (temperature at equilibrium and moisture absorption). The high ratio of RHA/AA and SiR/Ge resulted in a lower temperature at equilibrium (TAE) below 200°C and at moisture absorption below 16%. The optimum formulation for the geopolymer coating composite can be achieved when the RHA/AA ratio, SiR/Ge ratio, and sodium hydroxide concentration are set at 0.85, 0.70, and 14 M, respectively. SEM micrographs of samples with good fire retardant properties showed that the char residue of the geopolymer composite coating, which is a layer of excess silicone rubber, is porous and continuous, thus providing a shielding effect for the layer of geopolymer underneath. The sample with good moisture absorption showed the formation of a thin outer layer of silicone rubber without any cracks. The unreacted SiR formed a thin layer beneath the geopolymer composite matrix providing a good moisture barrier. Full article

Geopolymer foam (GF) uses a potassium activator and can be cured at high temperatures, which can improve its mechanical properties. In this study, we attempted to test this hypothesis by comparing the flexural and compressive strength, apparent density and fire resistance of GF. The composition of the GF used in the experiment included a potassium activator, basalt ground fiber and aluminum powder with a mass ratio to the binder of 0.45, 0.3 and 0.015, respectively. The samples were cured at room temperature and at 50, 70, 85 and 105 °C with a curing time of 2, 4, 6, 12 and 24 h. Then, the samples were kept until being tested on the third, seventh, 14th and 28th day. The results showed that the flexural and compressive strength and apparent density improved and stabilized after seven days at 85 °C. Furthermore, the GF exhibited a substantial increase after three days in its flexural strength by 111% and compressive strength by 122.9% at the optimal temperature of 85 °C for 2 h compared to the values at RT after 28 days. The GF had an apparent density of 0.558–0.623 g/cm³ on the 28th day. As a new alternative to aluminum materials, investigating the fire resistance of sandwich panels (an aluminum plate covered with a GF layer) is important for their safe impregnation. Sandwich panels with thicknesses of 10–20 mm were exposed to a gas fire. The test results showed that the sandwich panels had significantly improved fire resistance compared to unprotected panels. The longest fire resistance times for the aluminum plate coated with 20 mm of GF layer thickness was 7500 s. Thus, the GF coated on the aluminum plate exhibited superior fire resistance and a reduced heat transfer rate compared to uncoated panels. Full article

As a result of their significant importance and applications in vast areas, including oil and gas, building construction, offshore structures, ships, and bridges, coating materials are regularly exposed to harsh environments which leads to coating delamination. Therefore, optimum interfacial bonding between coating and substrate, and the reason behind excellent adhesion strength is of utmost importance. However, the majority of studies on polymer coatings have used a one-factor-at-a-time (OFAT) approach. The main objective of this study was to implement statistical analysis in optimizing the factors to provide the optimum adhesion strength and to study the microstructure of a rice husk ash (RHA)-based geopolymer composite coating (GCC). Response surface methodology was used to design experiments and perform analyses. RHA/alkali activated (AA) ratio and curing temperature were chosen as factors. Adhesion tests were carried out using an Elcometer and a scanning electron microscope was used to observe the microstructure. Results showed that an optimum adhesion strength of 4.7 MPa could be achieved with the combination of RHA/AA ratio of 0.25 and curing temperature at 75 °C. The microstructure analysis revealed that coating with high adhesion strength had good interfacial bonding with the substrate. This coating had good wetting ability in which the coating penetrated the valleys of the profiles, thus wetting the entire substrate surface. A large portion of dense gel matrix also contributed to the high adhesion strength. Conversely, a large quantity of unreacted or partially reacted particles may result in low adhesion strength. Full article

If the coating is sufficiently flexible, no tears, cracks, or debond will occur. Although geopolymers have a great potential as a coating material, research on the flexural properties is very limited. In this study, a three-point bending test and scanning electron microscope were used to investigate the flexural properties and microstructure of the geopolymer composite coating (GCC), respectively. Response Surface Methodology (RSM) consists of a combination of mathematical and statistical techniques, which is useful in modelling, analyzing, and optimizing responses that are influenced by several factors. It was used in determining the relationship between each factor and determining the best composition for the composite coating. Several factors were considered including ratio of activated alkaline (AA) solution (V₁), RHA/AA ratio (V₂), and curing temperature (V₃). Results showed that the RHA/AA ratio mostly influenced the response, followed by curing temperature while the ratio of AA was not significant. Lower V₂ and V₃ values provided the highest flexural strength and modulus. The optimum composition which provided the best coating of flexural properties were V₁ = 3.5, V₂ = 0.39, and V₃ = 45.7 °C. Microscopic images showed that coating with high flexural properties (ductile coating) exhibited minor and rough cracks as compared to that of coating with low flexural properties (brittle coating) which displayed a crack with a clean linear cut. Brittle coating was highly agglomerated and has a significant negative effect on the flexural properties. By developing the optimum composition, the GCC may potentially be a good alternative as a building construction coating material. Full article

The thermal and structural performance of geopolymer-coated polyurethane foam–phase change material capsules/geopolymer concrete composites was investigated. Three groups of concrete composites were prepared. The first was pure geopolymer (GP, control sample), the second was a GP/polyurethane foam (F) concrete composite, and the third was GP-coated polyurethane foam-phase change material capsules (GP-F-PCM)/GP concrete composites. Three different percentages of foam and GP-F-PCM capsules (25%, 50%, and 75%) were used in the composites. Thermal and U-value tests were conducted for all composites to characterize their peak temperature damping and insulation performances. The addition of 75% foam has been noticed to increase the back-surface temperature by 5.9 °C compared to the control sample. This may be attributed to the degradation of foam into low molecular constituents in the presence of a strong alkali. However, a temperature drop of 12.5 °C was achieved by incorporating 75% of GP-F-PCM capsules. The addition of 50% foam as a sandwich layer between two halves of a geopolymer concrete cube is also investigated. It was found that inserting a foam layer reduced the back-surface temperature by 3.3 °C, which is still less than the reduction in the case of GP-F-PCM capsules. The compressive strength was tested to check the integrity of the prepared concrete. At 28 days of aging, the compressive strength dropped from 65.2 MPa to 9.9 MPa with the addition of 75% GP-F-PCM capsules, which is still acceptable for certain building elements (e.g., nonloadbearing exterior walls). Generally, the best results were for the GP-F-PCM composite capsules as a heat insulator. Full article

The treatment of concrete surface using more durable material is one way to slow down the damage process of material, which can negatively affect durability of construction. This paper is aimed at testing the geopolymer-type coating materials of different composition while placing emphasis on various techniques of surface pre-treatments of concrete to which they were applied. The main composition variables were as follows: the fly ash fineness (original, ground) and the addition of washing-aggregate sludge. Four compositions were tested and compared with the composition based on cement binder. The cement mixture was prepared using the same fillers. The following techniques of surface pre-treatment of concrete were applied: brushing, pressure washing, and pressure washing followed by penetration, together with non-treated surface being used for comparison. The effect of the surface treatment technique was tested through the adhesion strength, which was executed at 2, 7, 28, and 120 days after application of the coating. The influence of the composition of geopolymer coating material was also discussed. Geopolymer-based mixtures achieved better adhesive strength than the cement-based mixture, regardless of surface treatment technique. The addition of sludge microfiller seems to be beneficial in improving the adhesive strength of geopolymer-type coating material. Full article