Search Results (74)

One-part geopolymer has emerged as a promising alternative to ordinary Portland cement. In this study, the effect of CaO dosage on the compressive strength of one-part geopolymers was systematically investigated, and its underlying modification mechanism was revealed via multi-scale characterizations including XRD, FTIR, TG, NMR and nitrogen adsorption–desorption. The results show that the compressive strength of the samples at all curing ages exhibits a trend of sharp initial decrease, followed by a slight rebound, and then a secondary decline with the increase in CaO dosage. All CaO-containing specimens exhibit significantly lower strengths than the CaO-free reference. Specifically, the reference sample achieves the highest 28-day compressive strength of 56.6 MPa. The strength of the sample at each curing age drops to the minimum at 5% CaO dosage, with a 28-day strength of only 17.9 MPa. Partial strength recovery of the sample is achieved at 7.5% CaO dosage. The strength deterioration is mainly attributed to the rapid hydration of CaO, which consumes free water and reactive silicon and hinders the generation of N-A-S-H gel rather than directly disrupting the aluminosilicate network. Meanwhile, the hydration products are continuously carbonated to form calcium carbonate, and the carbonation-induced volume expansion at excessive dosage may induce microcracks in the matrix that impair the structural integrity. Only at a moderate dosage of 7.5% CaO can a slight strength rebound be realized through the possible formation of C-S-H-type phases and the pore-filling effect. This study provides a theoretical basis for the material design and performance regulation of one-part geopolymers. Full article

One-part geopolymer mortars provide an alternative to cementitious materials by using dry activators and industrial by-products. This study evaluated a multi-precursor matrix containing slag, fly ash, ceramic powder, red mud, and 5% MgO, reinforced with polyvinyl alcohol (PVA), basalt, or micro-steel fibers at 0.4% and 0.8% by volume. Specimens were cured at 20 ± 2 °C or at 80 °C for 24 h and assessed for flowability, mechanical properties, ultrasonic pulse velocity (UPV), Böhme abrasion, 24 h water absorption, and sorptivity. XRD, FTIR, and SEM/EDS were used only to compare by heat-cured mixtures. The results showed that at 28-day, heat curing increased compressive strength by 39.5–71.8%, flexural strength by 29.2–134.4%, and UPV by 20.5–36.4%, while reducing sorptivity by 12.2–35.7% relative to ambient curing. PVA reduced flowability likely because of its hydrophilic surface and high surface area. For 0.8PVA, the flow diameter was 23.6% below the reference, whereas the 28-day heat-cured flexural strength reached 7.5 MPa, with the lowest abrasion thickness loss of 0.63 mm. Micro-steel mixtures maintained compressive strength comparable to the reference, reaching 72–73 MPa at 28-day. Heat curing reduced water absorption in PVA and basalt mixtures, whereas the reference and micro-steel mixtures showed insignificant change. Microstructural analyses suggested the formation of a more compact and reacted aluminosilicate matrix under heat-cured conditions. A screening life-cycle assessment, limited to the non-fiber-reinforced reference matrix, showed that heat-curing increased global warming potential by 7.6%, while the two solid activators contributed approximately 45% of the ambient-cured reference GWP. The findings indicate that heat curing significantly enhances the performance of one-part geopolymers, while fiber selection provides additional mechanical and durability improvements. Full article

This study examined the effects of coating waste tire aggregates (WTAs) with pumice, perlite, or diatomite, combined with polypropylene (PP) fiber addition, on the fresh, mechanical, transport, and durability properties of one-part hybrid geopolymer composites. Sixteen mixtures were produced using a Taguchi L16 design with a binder system of fly ash, CEM II/B-S cement, and sodium metasilicate powder. Coating type, WTA ratio, and PP fiber content were the key performance factors. Pumice coating performed best overall by improving the interfacial transition zone: 28-day compressive strength reached 15.5 MPa and flexural strength 1.60 MPa, while porosity and capillary water absorption decreased significantly. Among the studied WTA levels, 10% WTA yielded the most positive direct responses in compressive strength, flexural strength, toughness, and capillary water absorption, whereas higher contents weakened matrix continuity. The effect of PP fiber was response-dependent: 0.5% fiber maximized compressive strength and durability-related responses, while 2% fiber gave the greatest flexural strength and toughness; no single dosage was universally optimal. The pumice-coated series was also the most stable under high temperature, freeze–thaw, MgSO₄, and H₂SO₄ exposure. Overall, waste tire aggregates can be technically incorporated into one-part hybrid geopolymer composites; a dedicated life-cycle assessment is nevertheless required to quantify the net environmental benefit. Full article

Portland cement production accounts for roughly 8% of anthropogenic CO₂ emissions, driving interest in low-carbon geopolymer binders. One-part (“just-add-water”) geopolymers, which replace hazardous liquid activators with a dry, pre-blended solid activator, are especially suited to field deployment where handling safety and logistics are decisive. However, their formulation space is combinatorially vast, and trial-and-error development cannot efficiently navigate it. This paper reviews one-part geopolymer science, presents a new comparative and interpretable ML analysis of a published 80-mixture one-part fly-ash/ground granulated blast-furnace slag (GGBS, hereafter slag) geopolymer dataset from twelve studies, and proposes an AI-assisted design framework. The ML demonstration targets 28-day compressive strength only. Under leave-one-source-out (LOSO) cross-validation—the appropriate test for a literature-pooled dataset—gradient-boosted trees achieved R² = 0.61 (RMSE = 15.5 MPa; 95% bootstrap confidence interval on R², 0.44–0.75), well above a linear baseline (0.36), suggesting that non-linear structure transfers across studies; a random split gives a higher but less reliable R² = 0.90 on only 16 test mixtures. Because fly-ash and slag contents are near-perfectly anti-correlated ($r=-0.99$), we model the precursor axis as a single slag fraction descriptor; SHAP then identifies this precursor balance and the activator’s Na₂O dosage as the dominant statistical predictors of strength in this dataset, an ordering consistent with known activation chemistry; causal confirmation of these associations awaits the experimental validation stage of the proposed framework. Demonstrated for strength only, at paste level, the framework offers a transferable route toward multifunctional low-carbon binders for protective and infrastructure applications; the multifunctional extensions are proposed, but not yet demonstrated. Full article

Geopolymer research has usually focused on predicting compressive strength at specific curing ages, while the underlying strength-development behavior remains insufficiently understood. To address this gap, this study proposes a pathway-oriented framework for characterizing strength-development patterns in one-part geopolymers (OPGs). A compiled experimental database was established from published studies, and three dimensionless indices, namely the Early Strength Index (ESI), Mid-age Strength Index (MSI), and Late-stage Growth Potential (LGP), were introduced to quantify temporal strength-development behavior. Then, Gaussian Mixture Model (GMM) clustering was employed in the ESI–MSI–LGP feature space to identify latent strength-development pathways. Based on the available core dataset, three representative strength-development pathways were identified: Fast-hardening, Delayed-hardening, and Balanced-hardening. The Fast-hardening pathway exhibited the highest average ESI and MSI values, indicating rapid early- and mid-age strength attainment. The Delayed-hardening pathway showed lower ESI and MSI values but the highest LGP value, reflecting stronger later-age strength-growth potential after 7 days. The Balanced-hardening pathway was characterized by relatively low ESI, high MSI, and low LGP, suggesting accelerated strength development between 3 and 7 days. Further analysis of mix-design variables indicated that pathway formation was associated with the coupled effects of aggregate-to-binder proportion, activator chemistry, water availability, precursor composition, and curing conditions, rather than being controlled by a single dominant factor. Finally, a smooth probability-based strength-development map was established in the ESI–MSI feature space, providing a practical visualization tool for approximate pathway identification and preliminary mixture-selection support. The proposed framework shifts the focus from conventional strength prediction toward strength-development behavior characterization and offers new insights into the macroscopic hardening patterns of one-part geopolymers. Full article

This study presents the development of a one-part phosphate-activated geopolymer foam based on fayalite flotation residue from the copper industry. The solid activator consisted of triple superphosphate, enabling a dry-mix binder that requires only water addition prior to use. Foamed materials were characterized by XRD, FTIR, Mössbauer spectroscopy, DSC-TG, hot-stage microscopy, SEM-EDX and physical and mechanical testing. The foaming of the geopolymer reduced the densities between 0.753 and 2.15 g/cm³, relative porosities up to 73.6%, and compressive strengths ranging from 1.4 to 28.8 MPa. The foamed geopolymer maintained dimensional stability up to about 1000 °C. The thermal conductivity coefficient measured on large-sized specimen blocks was 0.099 W/mK at a density of 0.753 g/cm³. These results demonstrate that fayalite slag can be effectively utilized as a precursor for sustainable geopolymer foams combining low thermal conductivity, high thermal stability, and the utilization of industrial by-products. Full article

Rapid-repair mortars require high early-age strength, dimensional stability, and reliable substrate bond simultaneously, yet conventional alkali-activated materials (AAMs) have only partially met these requirements, and AAM feedstock base itself is contracting as blast furnace slag and fly ash availability declines under steel and power sector decarbonization. Thus, in this study, the systematic production of a one-part, rapid hardening repair mortar based on calcined clay (CC) and basic oxygen furnace slag (BOFS) is presented for the first time. Concurrently, a direct comparison of three distinct modifier families is conducted within this underutilized binding system. These modifiers consist of a soluble anion-active accelerator (sodium fluoride, NF), an Fe- and Na-bearing mineral residue (red mud, RM), and a reactive oxide (calcined alumina, CAL). Finally, the mechanistic connections between the modifier-induced phases and the macroscale mortar properties are analyzed and evaluated according to ASTM C928, ASTM C1600, and EN 1504-3 standards. The precursors were activated using solid sodium metasilicate, and the setting behavior, compressive strength development, drying shrinkage, substrate bond strength, and microstructural properties were determined for each mortar system. The results indicate that all formulations satisfied the R2 strength class for rapid hardening repair mortars as per ASTM C928 and the incorporation of NF markedly promoted the early-age reactions, reducing the setting time by up to 73% and increasing the 3 h compressive strength by up to 81% (12.8 MPa at 3 h) compared to the control mortar. Furthermore, RM, CAL, and NF effectively mitigated the drying shrinkage of the control mortar from approximately 4252 µƐ down to 162 µƐ. The bond strength of the repair mortars substantially improved through the addition of CAL and NF, fulfilling the R3 and R4 structural repair mortar requirements specified in EN 1504-3. Full article

Although geopolymer and alkali-activated binders are promoted as low-carbon OPC alternatives, their resource-centric performance remains complex and geographically dependent. This review examines these systems from a resource-efficiency perspective and evaluates alkaline activator demand; precursor availability, including fly ash, slag, calcined clays, and mining residues; and embodied energy across mix designs and curing regimes. Recent mechanical and durability analyses, together with life cycle assessments, reveal important trade-offs in alkali-activated geopolymer systems. Customized precursors may unintentionally compromise their inherent resource efficiency, while the declining availability of industrial waste increasingly competes with alternative waste valorization processes. Developing one-part activator systems and implementing data- or machine-optimized mix designs capable of handling extremely highly variable waste streams will be necessary to achieve meaningful reductions in mineral consumption, energy demand, and emissions. The study reframes these binders as enablers of urban mining and industrial symbiosis. Policy changes toward resource-oriented governance, including performance-based standards, carbon-responsive procurement, and more transparent end-of-waste legislation, are also needed to promote a circular material economy. Strategic, large-scale deployment requires the integration of regional resource mapping with predictive performance modeling to navigate resource constraints in the construction sector. Full article

This study investigated the development of a perlite waste-based geopolymer for stabilizing iron ore tailings byproduct (IOTB) for geotechnical applications. Mixtures containing 70/30 and 80/20 proportions of byproduct and geopolymer were produced using perlite waste as the precursor and NaOH as the alkaline activator through the one-part method. Raw and geopolymer-stabilized IOTB, air-cured for 7, 14, and 28 days, were evaluated by ICP-OES, XRF, pH, geotechnical characterization, compaction, permeability, SEM, and consolidated drained triaxial tests under confining stresses ranging from 250 to 2000 kPa. The selected mixture presented a maximum dry density of 1.8 g/cm³ and optimum moisture content of approximately 14%. XRD results indicated sodium aluminosilicate phases associated with geopolymerization, with mechanical characteristics comparable to feldspar-type structures, while the pH increased from 6.5 to 12.5. Triaxial tests indicated that elastoplastic behavior persisted regardless of the geopolymer addition; however, SEM images confirmed matrix–particle bonding at grain contacts without significant pore filling. The cohesive intercept increased from 0 kPa in the IOTB to 89.1 kPa and 179.2 kPa after 14 and 28 days of curing, respectively, while the friction angle showed a slight increase of up to 7.7%. Deviatoric stress at failure and energy absorption capacity also increased with curing time. Hydraulically, the permeability coefficient remained within the same order of magnitude (10⁻⁴ cm/s), varying from raw IOTB of 2.73 × 10⁻⁴ cm/s to 3.28 × 10⁻⁴ cm/s after 28 days. These results demonstrated that geopolymer stabilization enhanced mechanical performance without compromising drainage capacity, representing a technically viable and socio-environmentally sustainable solution. Full article

This study examines the carbonation behavior and CO₂ storage potential of a Ca-rich alkali-activated binder produced entirely from industrial residues-ladle furnace slag (LFS), coal ash (CA), and cement kiln dust (CKD). The system was designed as a one-part alkali-activated material (AAM), with CKD acting as an internal activator, and subjected to ambient curing, water curing, and accelerated CO₂ curing at ambient pressure. Phase evolution, microstructural development, and pore-structure characteristics were investigated using X-ray diffraction, FTIR spectroscopy, DSC–TG analysis, scanning electron microscopy, and X-ray micro-computed tomography, together with measurements of density, water absorption, and compressive strength. Loss-on-ignition measurements combined with chemical analysis were further used to quantify CO₂ uptake and evaluate the degree of carbonation of the binder system. CO₂ curing fundamentally altered the reaction pathway of the binder, shifting it from hydration-dominated to carbonation-controlled phase evolution, leading to the decomposition of calcium-bearing hydrates and complete carbonation of non-hydraulic γ-belite with the formation of vaterite, aragonite, and calcite. These transformations induced pronounced microstructural densification, reflected in a near-doubling of compressive strength (>48 MPa), increased apparent density, reduced water absorption, and simplified pore-network topology. A preliminary carbon footprint assessment indicates that the production of 1 m³ of the developed LFS–CA–CKD concrete generates about 14.36 kg CO₂-eq, while the carbonation process enables significant CO₂ sequestration, resulting in a net negative carbon balance. The results demonstrate that controlled carbonation is an effective post-treatment strategy for waste-derived alkali-activated binders, enabling simultaneous performance enhancement and permanent CO₂ sequestration. Full article

Low-carbon and highly printable cementitious materials are crucial for the practical application of extrusion-based three-dimensional concrete printing (3DCP). This study develops and optimizes a one-part alkali-activated concrete suitable for 3D printing through an integrated experimental and evaluation approach. An orthogonal experimental design was employed to investigate the effects of precursor ratio (ground granulated blast-furnace slag, GGBFS, to fly ash, FA), water-to-binder ratio, activator dosage, and retarder content on fresh-state properties, rheological behavior, setting characteristics, and mechanical performance. The optimal mixture was determined using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) multi-criteria decision method. The mixtures exhibited suitable rheology, with a yield stress of 90–141 Pa and a plastic viscosity of 3.5–7.2 Pa·s, a setting time of 40–96 min, and mechanical performance with compressive and flexural strengths of 29–71 MPa and 4.2–6.9 MPa, respectively. The optimal mixture provided a 95-min printing open time and an acceptable pumping pressure of 1.77 MPa, while full-scale tests confirmed stable extrusion and good print quality. Furthermore, within the defined cradle-to-gate, materials-stage boundary and the adopted inventory factors, the optimized alkali-activated mixture exhibited an embodied CO₂ emission of 0.113 kg CO₂/L, which is approximately 61% lower than that of the reference cement-based printable mixture. The proposed approach provides a systematic framework for designing low-carbon, high-performance one-part alkali-activated materials for extrusion-based 3D concrete printing applications. Full article

The cement industry is a major source of anthropogenic CO₂ emissions due to its energy-intensive production process and calcination of limestone. Producing one ton of cement emits approximately one ton of CO₂, and cement accounts for about 5% to 8% of global CO₂ emissions. In this context, cement-less one-part (“just-add-water”) ambient-cured geopolymer concrete (GPC) has gained attention due to its environmental friendliness and practicality for large-scale cast-in-situ construction. However, field adoption remains limited, mainly due to the scarcity of data on mechanical properties and durability, as well as the lack of widely accepted standards and specifications. This paper is part of the larger research on tensile performance of anchors embedded in GPC. It is well understood that the tensile performance of anchors installed in concrete substrate is largely influenced by their effective embedment depth and the substrate’s mechanical properties, particularly the fracture energy and modulus of elasticity. Therefore, prior to the investigation of the tensile performance of anchors in GPC, it is crucial to understand the mechanical behaviour of the GPC substrate itself. This study examined key parameters that influence the compressive strength of one-part ambient-cured slag/fly ash-based GPC. The alkali content, slag content, water-to-solid (W/S) ratio, and aggregate content were investigated. Additionally, various mechanical properties such as uniaxial tensile strength, splitting tensile strength, elastic modulus, and fracture energy of the hardened GPC are presented. The test results revealed that higher slag and activator content enhanced compressive strength, whereas a higher aggregate content reduced the strength. The strength gain was also attributed to higher alkali content, lower W/S ratio, and increased binder content; however, excessive alkali and an overly low W/S ratio caused rapid setting due to accelerated reaction kinetics. The 7-day compressive strength ranged from 62% to 78% of the 28-day strength, while there was no notable strength gain after 28 days of curing. The developed GPC attained compressive strengths of over 40 MPa at 28 days and 50 MPa at 56 days. The uniaxial tensile strength test demonstrated a ratio of 0.87 relative to splitting tensile strength. The findings also indicated that the aggregate conditions and curing regimes (whether using as-is aggregates with moisture curing or oven-dried aggregates with sealed curing) had no meaningful effect on the mean compressive strength of GPC and its reproducibility. Full article

Amid growing environmental concerns, resource depletion, and the pressing challenges of industrial waste management, this study investigates the potential of magnesium slag (MS) as a sustainable alternative binder in the production of one-part geopolymer concretes (OPGCs). The objective is to reduce reliance on conventional cementitious materials while promoting the valorization of industrial by-products in construction practices. For this purpose, ten different mixtures were designed by replacing ground granulated blast furnace slag (GGBS), the conventional aluminosilicate precursor, with MS, an innovative aluminosilicate precursor, at replacement levels of 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, and 100% by weight, using a solid activator. The fresh and hardened properties of these mixtures were systematically evaluated through slump, setting time, density, ultrasonic pulse velocity (UPV), and strength tests, while microstructural characterization was also conducted using scanning electron microscopy (SEM) coupled with energy-dispersive X-ray spectroscopy (EDX) to further investigate the geopolymerization process, elemental distribution, and the role of MS in binder formation in OPGC. The results revealed that MS incorporation significantly influenced both workability and mechanical performance, and it was confirmed that MS actively participates in geopolymerization and can be effectively utilized up to a certain threshold. Replacement levels up to 30% were found to maintain acceptable mechanical performance, providing evidence that MS is a promising precursor for developing sustainable OPGC. Full article

Recent studies have highlighted the potential for production of an alternative sodium silicate in powder obtained by mixing NaOH with rice husk ash, followed by a dissolution and drying process. This alternative sodium silicate, when mixed with metakaolin and dried under special conditions, results in an eco-friendly one-part alkali-activated binder (OPAAB). However, the durability performance of OPAAB incorporating RHA-derived sodium silicate remains largely unexplored. This study focuses on an experimental investigation of OPAAB mortar durability, analyzing permeability, high-temperature exposure, wet-and-dry cycles, and resistance to aggressive environments (sulfate and acid attack). A two-part mix mortar made with the same precursors was used as a reference. It was found that the OPAAB mortars were not affected by the wet-and-dry cycles nor the sulfate attack. Exposure to high temperature (900 °C for 1 h) did not cause specimen failure, which had a residual compressive strength higher than 5 MPa. Finally, exposure to sulfuric acid for 56 days decreased the mechanical strength of the mortars, but all the specimens maintained a residual compressive strength higher than 4 MPa. The durability performance of the mortars produced with OPAAB incorporating RHA-derived sodium silicate was similar to the two-part mix mortars (reference), demonstrating technical feasibility and advancing the understanding of durability aspects for application in civil construction. Full article

This study employed machine learning to investigate the mechanical behavior of one-part geopolymer (OPG)-stabilized soil subjected to acid erosion. Based on the unconfined compressive strength (UCS) data of acid-eroded OPG-stabilized soil, eight machine learning models, namely, Adaptive Boosting (AdaBoost), Decision Tree (DT), Extra Trees (ET), Gradient Boosting (GB), Light Gradient Boosting Machine (LightGBM), Random Forest (RF), Support Vector Machine (SVM), and eXtreme Gradient Boosting (XGBoost), along with hyper-parameter optimization by Genetic Algorithm (GA), were used to predict the degradation of the UCS of OPG-stabilized soils under different durations of acid erosion. The results showed that GA-SVM (R² = 0.9960, MAE = 0.0289) and GA-XGBoost (R² = 0.9961, MAE = 0.0282) achieved the highest prediction accuracy. SHAP analysis further revealed that solution pH was the dominant factor influencing UCS, followed by the FA/GGBFS ratio, acid-erosion duration, and finally, acid type. The 2D PDP combined with SEM images showed that the microstructure of samples eroded by HNO₃ was marginally denser than that of samples eroded by H₂SO₄, yielding a slightly higher UCS. At an FA/GGBFS ratio of 0.25, abundant silica and hydration products formed a dense matrix and markedly improved acid resistance. Further increases in FA content reduced hydration products and caused a sharp drop in UCS. Extending the erosion period from 0 to 120 days and decreasing the pH from 4 to 2 enlarged the pore network and diminished hydration products, resulting in the greatest UCS reduction. The results of the study provide a new idea for applying the ML model in geoengineering to predict the UCS performance of geopolymer-stabilized soils under acidic erosion. Full article