Search Results (60)

The forming methodology influences the physicochemical, mechanical, and microstructural properties. In this study, which aims to develop a geopolymeric material for potential insulation applications in buildings such as vertical walls, geopolymers were developed using industrial wastes from different industries: slate stone cutting sludge (SSCS) and chamotte (CH) were used as precursors, and olive stone bottom ash (OSBA) and sodium silicate (Na₂SiO₃) were used as alkaline activators. Two forming methods were evaluated: uniaxial pressing and casting of the material, varying the forming method and the liquid/solid ratio. The results showed that the pressed geopolymers achieved higher bulk densities (up to 2.13 g/cm³) and significantly higher compressive strength (28.04 MPa at 28 days), attributable to a higher compactness and degree of geopolymer reaction. In contrast, the casting geopolymers exhibited surface efflorescence, related to slower curing and higher porosity, which reduced their compressive strength (17.88 MPa). In addition, the pressed geopolymers showed better thermal stability and fire performance. These results demonstrate that the variation of the forming method has a direct influence on the material properties of geopolymers, and that the pressing process allows for a reduction of the alkaline activator content, thus reducing its environmental footprint. Full article

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

Geopolymers, as sustainable alternatives to conventional cement, face application limitations due to pronounced drying shrinkage. This study systematically investigates the effects of cement incorporation (0–40%) on the drying shrinkage mitigation and performance evolution of metakaolin-based geopolymers (MKBGs) through multi-scale characterization of mechanical properties, reaction kinetics, and pore structure refinement. Key findings reveal that 10% cement addition optimally reduces drying shrinkage through pore structure densification and elastic modulus enhancement. The cement–geopolymer hybrid system exhibited a distinctive dual-reaction mechanism: cement hydration produced C-S-H gels that refined the pore structure while simultaneously competing with and delaying the geopolymerization kinetics, as demonstrated by the extended duration of the reaction exotherm. However, cement contents exceeding 20% induce detrimental self-desiccation shrinkage, resulting in net shrinkage amplification. Microstructural analysis confirms that the optimal 10% cement dosage achieves synergistic phase evolution, with N-A-S-H and C-S-H gels co-operatively improving mechanical strength and dimensional stability. This work provides quantitative guidelines for designing shrinkage-resistant geopolymer composites through controlled cement hybridization. Full article

As an innovative inorganic cementitious material, geopolymer holds significant application potential in the field of road engineering. Based on the theoretical basis of industrial solid waste resource utilization and combined with geopolymerization technology, this study investigates the feasibility of applying lead–zinc-tailing-based geopolymer–stabilized aggregate (LZT-GSA) in road engineering through systematic mechanical property tests, durability assessment, and microstructural characterization. The study focuses on the influence of cementitious material admixture on the unconfined compressive strength, splitting tensile strength, compressive resilient modulus, drying shrinkage, and freeze–thaw cycle resistance of LZT-GSA. The experimental results demonstrated that LZT-GSA exhibited excellent properties in terms of mechanical performance and durability, which were remarkably better than those of conventional cement-stabilized aggregates (CSA). However, the incorporation of a small amount of lead–zinc tailing alone can weaken the mechanical properties of CSA. The drying shrinkage of LZT-GSA was slightly higher than that of CSA due to the difference in the intrinsic reaction mechanism between LZT-GSA and CSA. The effective cementing and wrapping effect of geopolymer gel on discrete aggregate dramatically improves the structural compactness of LZT-GSA. The leaching concentration of heavy metals in LZT-GSA is far below the requirements of environmental protection standards. These research results not only provide theoretical support for the resource utilization of lead–zinc tailings, but also lay a technical foundation for its practical application in road engineering. Full article

This paper focuses on the possibility of using phosphogypsum, which is a residue from the production of orthophosphoric acid as an additional source of calcium and the use of spent caustic as an alkaline activator for production of ceramic materials in construction industry. The use of the above-mentioned waste will allow to increase fraction of calcium, sodium and silicate needed for the geopolymerization process and improve properties of material. This review presents a description of the geopolymerization process and the influence of alkaline activator on the reactions occurring in ceramic materials. Collected information, which confirm the possibility of using post-production waste from chemical industry as components for the production of building materials. Full article

This study evaluated the effect of precursor particle size and calcium hydroxide (CH) incorporation on the microstructure, compressive strength, and rheological properties of clay brick waste (BW)-based geopolymers. Rheological analyses were used to evaluate the fresh state of the geopolymers. XRD, SEM, and EDS analyses were performed to analyze the microstructure. The results showed that the particle size reduction in BW and the incorporation of CH significantly contributed to obtaining better compressive strength in the geopolymers. Furthermore, the particle size reduction decreased the yield stress, plastic viscosity, and hysteresis area of the geopolymers, while the incorporation of CH promoted the opposite effect. Increasing the CH incorporation content accelerated the geopolymerization reactions and reduced the workability of the geopolymers over time. However, since the milling process is costly, milling BW for 2 h was more efficient from a technical–economic point of view. In addition, the incorporation of CH not only promoted the early hardening of the geopolymers when necessary, but also contributed to the improvement of the compressive strength through matrix densification. Therefore, the results of this study show the definition of more efficient material proportions for geopolymers using waste as an aluminosilicate source. Full article

The use of industrial residues in civil construction is an exciting alternative to mitigate environmental impacts and promote the circular economy. This work developed new compositions of geopolymer mortars activated by NaOH from fine kaolin residue (RCF), coarse kaolin residue (RCG) and granite (RG). All residues were benefited and characterized by chemical analysis (X-ray fluorescence), mineralogical phases (X-ray diffraction) and granulometry (laser granulometry). Additionally, the RCF was calcined at 650 °C for 2 h (RCFC) to produce metakaolin, which is the starting point for the geopolymer reaction. A mixture of experimental designs was accomplished to evaluate the water/binder factor (W_exp (%)) necessary for new geopolymer mortar compositions to reach the consistency index (260 mm, ASTM C1437-15) and the effect of different curing conditions on the simple compressive strength (SCS). The geopolymeric compositions with RCFCs, pre-cured at room temperature, exhibited the highest W_exp% values (>40%) and significant SCS, with curing conditions A and B reaching 6 MPa and 7 MPa, respectively. Such behavior can be explained by the fact that the pre-curing step at room temperature keeps the system humidity relatively high, favoring the dissolution of Si⁴⁺ and Al³⁺ ions and, therefore, increasing the Si/Al ratio, which positively influences the geopolymerization kinetics reaction. Full article

This study aims to compare the effects of three calcium compounds on the workability, setting time and mechanical properties of red mud (RM)–blast furnace slag (BFS)-based geopolymers. The crystalline phase, hydration process and microstructure of RM-BFS-based geopolymers were characterized by X-ray diffraction (XRD), heat evolution, X-ray photoelectron spectroscopy (XPS), and scanning electron microscope (SEM) tests. The results showed that an appropriate amount of calcium compounds can improve the flowability and compressive strength of the geopolymers, but the excessiveness causes a decrease in strength due to rapid hardening. Other than calcium carbonate, both calcium oxide and calcium chloride played important roles in accelerating the setting times of RM-BFS-based geopolymers. The acceleration in the setting times of geopolymers could be attributed to the calcium hydroxide produced by the dissolution of the calcium compounds, which also provides nucleation sites for the geopolymerization reaction. This study gives new insights into the effect of calcium on the setting times and mechanical properties of geopolymers in the geopolymerization process. Full article

Geopolymers are in many applications a perfect alternative to standard cements, especially regarding the sustainable development of green building materials. This experimental study therefore deals with the investigation of different factors, such as the water content and the binder to aggregate ratio, and their influence on the workability of fresh mortar and its mechanical properties and porosity on different size scales. Although increasing the water content improved the workability and flow behaviour of the fresh mortar, at the same time, a reduction in compressive strength in particular and a lesser reduction in flexural strength could be demonstrated. This finding can be attributed to an increase in capillary porosity, as demonstrated by capillary water uptake and mercury intrusion porosimetry measurements. At the same time, the increasing water content led to an improved deaeration effect (low air void content) and to initial segregation (see the µXCT measurements). An alternative approach to enhance the compressive and flexural strengths of the mortar specimens is optimization of the binder to aggregate ratio from 1 to 0.25. This study paves the way for a comprehensive understanding of the underlying chemistry of the geopolymerization reaction and is crucial for the development of sustainable alternatives to cementitious systems. Full article

The increasing global demand for cement significantly impacts greenhouse gas emissions and resource consumption, necessitating sustainable alternatives. This study investigates fresh geopolymer (GP) pastes incorporating 20 wt.% of five industrial wastes—suction dust, red mud from alumina production, electro-filter dust, and extraction sludges from food supplement production and from partially stabilized industrial waste—as potential replacements for traditional cement. Consistent synthesis methods are used to prepare the geopolymers, which are characterized for their physicochemical, mechanical, and biological properties. Ionic conductivity and pH measurements together with integrity tests, thermogravimetry analysis (TGA), and leaching analysis are used to confirm the stability of the synthesized geopolymers. Fourier-transform Infrared (FT-IR) spectroscopy is used to follow geopolymerization occurrences. Results for ionic conductivity, pH, and integrity revealed that the synthesized GPs were macroscopically stable. TGA revealed that the main mass losses were ascribable to water dehydration and to water entrapped in the geopolymer networks. Only the GP filled with the powder of the red mud coming from alumina production experienced a mass loss of 23% due to a partial waste degradation. FT-IR showed a red shift in the main Si-O-(Si or Al) absorption band, indicating successful geopolymer network formations. Additionally, most of the GPs filled with the wastes exhibited higher compressive strength (37.8–58.5 MPa) compared to the control (22 MPa). Only the GP filled with the partially stabilized industrial waste had a lower mechanical strength as its structure was highly porous because of gas formation during geopolymerization reactions. Despite the high compressive strength (58.5 MPa) of the GP filled with suction dust waste, the concentration of Sb leached was 25 ppm, which limits its use. Eventually, all samples also demonstrated effective antimicrobial activity against Escherichia coli and Staphylococcus aureus due to the alkaline environment and the presence of metal cations able to react with the bacterial membranes. The findings revealed the possibility of recycling these wastes within several application fields. Full article

This research undertakes a comparative study between compacted phosphate-based (CPG) and alkaline-based (CAG) geopolymeric materials. The obtained materials underwent comprehensive evaluation through mechanical, physical, and chemical analyses. CPG exhibited superior mechanical strength, demonstrating an exponential growth with curing age in contrast to CAG. Both materials exhibited stable density over time, with CPG displaying a notably higher density attributed to its enhanced reactivity in an acidic medium. Dimensional variations revealed stable dimensions for CPG and subtle shrinkage for CAG, potentially associated with an observed efflorescence phenomenon. Visual assessments during water immersion highlighted the enhanced stability of CPG. Chemical analyses confirmed the persistence of mineralogical phases, such as quartz and illite, and the emergence of an amorphous geopolymeric network in both CPG and CAG samples. CPG materials featured aluminum phosphate phases, reinforcing structural integrity, while CAG materials exhibited sodium carbonate phases, introducing impurities, elucidating the superior performance of CPG over CAG. For the formation kinetics, CPG exhibited a faster reaction time than CAG, as evidenced by the evolution of pH, densification rate, and FTIR band over curing time. Full article

This study aims to investigate the geopolymerization reaction of geopolymer foams produced with three different foaming agents: aluminum powder, zinc powder, and hydrogen peroxide. The geopolymerization reaction of geopolymer foam was monitored using the ²⁷Al and ²⁹Si magic angle spinning (MAS) nuclear magnetic resonance (NMR) spectroscopy technique. ²⁷Al MAS-NMR was used to monitor the reaction at an early stage, while ²⁹Si and ²⁷Al MAS-NMR analyses were employed at specific time intervals of 3, 6, 10, 15, and 28 days to examine the changes that occurred in the formed gel over time. We discussed in detail how the type of foaming agent used and the duration of the reaction both influence the quantity of gel formed and the amount of remnant fly ash. Our findings indicate that the type of foaming agent used affects the formation and structure of the gel, with aluminum powder leading to the highest gel formation. Additionally, the duration of the reaction plays a significant role in determining the quantity of remnant fly ash, with longer reaction times resulting in decreased fly ash content. This study sheds light on the relevance of understanding the role of foaming agents in the geopolymerization reactions of geopolymer foams and the influence of reaction time on the formed gel properties. Full article

Geopolymers exhibit broad application prospects, including construction and radiation shielding, which require excellent mechanical performances. However, investigations on the nature of geopolymerization reactions and their consequential impact on mechanical performance are still vague. In this study, the effect of the major factors of Si/Al ratio and curing time on the geopolymerization reaction and flexural strength were studied based on the microstructure evolution and chemical bonding formation analyzed using the SEM, FTIR, peak deconvolution, and XRD methods. The microstructure of geopolymers was transferred from initially layered smooth particles of kaolinite to a 3D network porous structure, corresponding to sodalite. A spectrum exclusive to the geopolymer structure occurred at 973 cm⁻¹, corresponding to the sodium aluminum silicate hydrate (N-A-S-H) links, the integral area of which represents the degree of geopolymerization reaction. Furthermore, a controllable reaction degree was achieved by adjusting the Si/Al ratio and curing time, where the maximum reaction degree of 55% was achieved at a Si/Al ratio of 1.94 when cured for 7 d. The correlation between the flexural strength and reaction degree was found to follow a proportional relationship, achieving a flexural strength of 21.11 MPa with a degree of 45%. This study provides insight into the development of mechanical strength through controlling the reaction process. Full article

The optimal proportion of alkali-activated steel slag–slag cementitious materials is investigated by considering the combined effects of steel slag content, alkali content, water glass modulus, and water–binder ratio using the Box–Behnken design in response surface methodology. Qualitative and semi-quantitative analyses of X-ray diffraction (XRD) patterns and scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS) images are conducted. The microstructural mechanism is elucidated based on the chemical composition, surface morphology, and microscale pore (crack) structures of the samples. A microreaction model for the alkali-activated steel slag and slag is proposed. The optimal composition for alkali-activated steel slag–slag cementitious materials is as follows: steel slag content, 38.60%; alkali content, 6.35%; water glass modulus, 1.23; and water–binder ratio, 0.48. The strength values predicted by the response surface model are p_1d = 32.66 MPa, p_7d = 50.46 MPa, and p_28d = 56.87 MPa. XRD analysis confirms that the compressive strength of the sample is not only influenced by the amount of gel formed, but also, to a certain extent, by the CaCO₃ crystals present in the steel slag, which act as nucleation sites. The SEM-EDS results confirm that the gel phase within the system comprises a hydrated calcium silicate gel formed through the reaction of volcanic ash and geopolymer gel formed through geo-polymerization. Analysis of the pore (crack) structure reveals that the compressive strength of the specimens is primarily influenced by porosity, with a secondary influence of the pore fractal dimension. Full article

Geopolymers have been proposed as a green alternative to Portland cement with lowered carbon footprints. In this work, a geopolymeric mortar obtained using waste materials is studied. Fly ash, a waste generated by coal combustion, is used as one of the precursors, and waste glass as lightweight aggregates (LWAs) to improve the thermal performance of the mortar. The experimental study investigates the effect of varying the alkali activating solution (AAS) amount on the workability, compressive strength, and thermal conductivity of the mortar. Indeed, AAS represents the most expensive component in geopolymer production and is the highest contributor to the environmental footprint of these materials. This research starts by observing that LWA absorbs part of the activating solution during mixing, suggesting that only a portion of the solution effectively causes the geopolymerization reactions, the remaining part wetting the aggregates. Three mixes were investigated to clarify these aspects: a reference mix with a solution content calibrated to have a plastic consistency and two others with the activating solution reduced by the amount absorbed by aggregates. In these cases, the reduced workability was solved by adding the aggregates in a saturated surface dry state in one mix and free water in the other. The experimental results evidenced that free water addiction in place of a certain amount of the solution may be an efficient way to improve thermal performance without compromising the resistance of the mortar. The maximum compressive strength reached by the mortars was about 10 MPa at 48 days, a value in line with those of repair mortars. Another finding of the experimental research is that UPV was used to follow the curing stages of materials. Indeed, the instrument was sensitive to microstructural changes in the mortars with time. The field of reference of the research is the rehabilitation of existing buildings, as the geopolymeric mortars were designed for thermal and structural retrofitting. Full article