Search Results (40)

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

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

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

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

The disposal of industrial waste poses a significant environmental challenge, often leading to pollution and degradation of surrounding and terrestrial ecosystems. This study investigates the sustainable valorization of such wastes through the development of one-part geopolymer mortars. Solid sodium silicate was employed as a dry alkali activator for binary blends comprising ground granulated blast-furnace slag (GGBS), clay brick powder (CBP), steel slag (SS), and fly ash (FA), with all mixtures cured under ambient conditions. The mortars were evaluated in terms of fresh properties (flow and setting time) and hardened characteristics, including compressive strength, density, water absorption, and porosity. Durability performance was assessed through mass loss, visual degradation, and compressive strength retention following exposure to acidic (H₂SO₄, HCl) and sulfate environments. Microstructural characterization using XRD, SEM, and FTIR provided insight into the mechanisms of gel formation and degradation in aggressive media. The results revealed that incorporating 5% FA into GGBS-based mortars enhanced 28-day compressive strength by 21.7% compared with the control mix. The inclusion of industrial by-products promoted the formation of C–S–H and C–(A)–S–H gels, contributing to a denser and more refined microstructure. Overall, the findings demonstrate that one-part geopolymer mortars offer a promising, eco-efficient, and durable alternative to traditional cementitious systems, while also addressing safety and handling concerns associated with liquid alkaline activators used in conventional two-part geopolymer formulations. Full article

This article focuses on developing and characterizing one-part rock-based geopolymer slurries using Brazilian rock precursors for well construction and plugging and abandonment (P&A) applications. The study presents the fluid-state and solid-state properties of these geopolymers, as well as X-ray diffraction (XRD) and Scanning Electron Microscopy (SEM), to understand the microstructure of the precursors and the reaction level. The effect of temperature and pressure on the development of compressive strength was investigated. By altering these parameters, the study aimed to examine the impact of various conditions on the strength development of the geopolymer material. Technological tests were conducted following API RP 10B-2. Compressive strength tests were conducted to determine early strength development and thickening time. Post-curing Rietveld refinement by XRD was performed to examine the microstructure and reactivity. Finally, fluid-state properties were also assessed, including thickening time and viscosity. The strength development of geopolymers is observed to be time- and temperature-dependent, as shown by UCS results. The final product has a dense structure, and its long-term performance will require evaluation to determine its sealing capability and volume change as a barrier material. The results highlight the novelty of employing locally available Brazilian rock precursors in one-part geopolymer formulations and provide a scientific basis for their potential application as sustainable alternatives to conventional cements in well construction and abandonment. Full article

Cementation using Ordinary Portland Cement (OPC) remains the standard method for conditioning low- and intermediate-level radioactive waste, including Spent Ion Exchange Resins (SIERs). This work presents an integrated strategy involving thermal pretreatment to minimize waste volume and eliminate organic constituents, followed by encapsulation within three distinct binders: CEM I, CEM III, and a novel one-part geopolymer. The one-part geopolymer system represents a significant operational innovation, enabling safe and simple “just-add-water” processing and avoiding the need to handle alkaline solutions. The proposed geopolymer, synthesized from metakaolin, blast furnace slag, and solid sodium silicate, was systematically benchmarked against conventional OPC matrices (CEM I, CEM III) by assessing their capacity to immobilize thermally treated SIER ashes under accelerated leaching conditions. For benchmarking, leaching indices for Cs and Sr were determined following the ANSI/ANS 16.9 standard protocol in three representative environments simulating operational and long-term repository scenarios, providing a quantitative evaluation of radionuclide retention and matrix durability. Results indicate that the one-part geopolymer improved leaching indices for Cs and Sr compared to both cementitious binders and complied with regulatory waste acceptance criteria. The comparative results highlight the potential of geopolymer technology to increase waste loading efficiencies and improve long-term safety, establishing a robust framework for future radioactive waste management approaches. Full article

One-part geopolymers (OPG) offer a low-carbon alternative to Portland cement, yet mix design remains largely empirical. This study couples machine learning with SHAP (Shapley Additive Explanations) to quantify how mix and curing factors govern performance in Ca-containing OPG. We trained six regressors—Random Forest, ExtraTrees, SVR, Ridge, KNN, and XGBoost—on a compiled dataset and selected XGBoost as the primary model based on prediction accuracy. Models were built separately for four targets: compressive strength at 3, 7, 14, and 28 days. SHAP analysis reveals four dominant variables across targets—Slag, Na₂O, Ms, and the water-to-binder ratio (w/b)—while the sand-to-binder ratio (s/b), temperature, and humidity are secondary within the tested ranges. Strength evolution follows a reaction–densification logic: at 3 days, Slag dominates as Ca accelerates C–(N)–A–S–H formation; at 7–14 days, Na₂O leads as alkalinity/soluble silicate controls dissolution–gelation; by 28 days, Slag and Na₂O jointly set the strength ceiling, with w/b continuously regulating porosity. Interactions are strongest for Slag × Na₂O (Ca–alkalinity synergy). These results provide actionable guidance: prioritize Slag and Na₂O while controlling w/b for strength. The XGBoost+SHAP workflow offers transparent, data-driven decision support for OPG mix optimization and can be extended with broader datasets and formal validation to enhance generalization. Full article

The global cement industry remains a significant contributor to carbon dioxide (CO₂) emissions, prompting substantial research efforts toward sustainable construction materials. Lithium slag (LS), a by-product of lithium extraction, has attracted attention as a supplementary cementitious material (SCM). This review synthesizes experimental findings on LS replacement levels, fresh-state behavior, mechanical performance (compressive, tensile, and flexural strengths), time-dependent deformation (shrinkage and creep), and durability (sulfate, acid, abrasion, and thermal) of LS-modified concretes. Statistical analysis identifies an optimal LS dosage of 20–30% (average 24%) for maximizing compressive strength and long-term durability, with 40% as a practical upper limit for tensile and flexural performance. Fresh-state tests show that workability losses at high LS content can be mitigated via superplasticizers. Drying shrinkage and creep strains decrease in a dose-dependent manner with up to 30% LS. High-volume (40%) LS blends achieve up to an 18% gain in 180-day compressive strength and >30% reduction in permeability metrics. Under elevated temperatures, 20% LS mixes retain up to 50% more residual strength than controls. In advanced systems—autoclaved aerated concrete (AAC), one-part geopolymers, and recycled aggregate composites—LS further enhances both microstructural densification and durability. In particular, LS emerges as a versatile SCM that optimizes mechanical and durability performance, supports material circularity, and reduces the carbon footprint. Full article