Quarry Waste as Precursors in Geopolymers for Civil Engineering Applications: A Decade in Review

The Precursors Used for Developing Geopolymer Composites for Circular Economy-A Review

Considering recent climate changes, special importance is given to any attempt to depollute and protect the environment. A circular economy seems to be the ideal solution for the valorization of mineral waste, resulting from various industrial branches, by reintroducing them in the process of obtaining alternative building materials, more friendly to the environment. Geopolymers can be considered as a promising option compared to Portland cement. Information about the influence of the composition of the precursors, the influence of the activation system on the mechanical properties or the setting time could lead to the anticipation of new formulations of geopolymers or to the improvement of some of their properties. Reinforcement components, different polymers and expansion agents can positively or negatively influence the properties of geopolymers in the short or long term.

Research on the Mechanical Properties and Microstructure of Modified Silt Sediment Geopolymer Materials

The treatment of silted sediment in the river is a global problem. The accumulation of waste sediment will lead to an adverse impact on the environment. In this paper, the silted sediment was reused to produce geopolymer composite materials via alkali-activated gelling modification. The effects of the modifiers of sodium silicate solution, quicklime, and Na₂SO₄ admixture, and the dosage of the slag, fly ash, and silica fume admixture, and curing conditions and age, on the compressive strength and microstructure of the geopolymer-modified sediment materials were studied. The crystalline phase and hydration products of the modified sediment geopolymer composites were analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), respectively. A compressive strength test was conducted to evaluate the mechanical properties of the composites. The results showed that the type and dosage of modifier, amount of mineral admixture additive, cure conditions, and cure age had significant effects on the mechanical properties of the composites. The effect of the addition of mineral admixture on the compressive strength of the modified sediment specimens was more noticeable than that of the modifier. The compressive strength of the geopolymer-modified specimens was greatly increased by the addition of mineral dopants. When 10 wt.% silica fume is added, the compressive strength reaches a maximum value of 33.25 MPa at 60 days. The SEM-EDS results show that the C-S-H gels and C-A-S-H gels were the main hydration products. The results indicate that river siltation sediment is an excellent raw material for geopolymer-modified materials. It is feasible to produce reliable and sustainable hydraulic engineering materials by using river sediment geopolymer-modified materials.

Mixture Optimization of Concrete Paving Blocks Containing Waste Silt

Most of the waste materials recycled for the production of new construction materials are by-products of various manufacturing processes, such as the aggregate washing process. Recycling such materials is of paramount importance since it could reduce the adverse environmental impacts resulting from landfilling. Various studies have attempted to recycle different types of waste materials and by-products into concrete paving blocks. However, the availability of literature on concrete paving blocks containing waste silt is quite scarce. Thus, the current paper focuses on mix design optimization and production of concrete paving blocks containing high amounts of waste silt resulting from the aggregate production process. Using the mixture Design of Experiments (DOE), 12 sets of concrete paving blocks with different aggregate blends were produced to optimize the mix design. Once the final mix design was achieved, the physical and mechanical properties of the concrete paving blocks were investigated following the EN 1338 standard. Shape and dimension measurements and various tests, including water absorption, tensile splitting strength, abrasion resistance, and slip/skid resistance were conducted on the experimental concrete paving samples. Overall, the produced concrete paving blocks showed promising properties for future applications in pedestrian walking paths.

Geopolymers as Sustainable Material for Strengthening and Restoring Unreinforced Masonry Structures: A Review

Unreinforced masonry (URM) structures are vulnerable to earthquakes; thus, materials and techniques for their strengthening and restoration should be developed. However, the materials used in some of the existing retrofitting technologies for URM and the waste produced at its end-of-life are unsustainable. The production of ordinary Portland cement (OPC) worldwide has enormously contributed to the global carbon footprint, resulting in persistent environmental problems. Replacing OPC with geopolymers, which are more sustainable and environmentally friendly, presents a potential solution to these problems. Geopolymers can replace the OPC component in engineering cementitious composites (ECC), recommended to strengthen and restore URM structures. In the present paper, the state-of-the-art knowledge development on applying geopolymers in URM structures is discussed. The discussion is focused on geopolymers and their components, material characterization, geopolymers as a strengthening and restoration material, and fiber-reinforced geopolymers and their application to URM structures. Based on this review, it was found that the mechanical properties of geopolymers are on par with that of OPC; however, there are few studies on the mentioned applications of geopolymers. The characterization of geopolymers’ mechanical and physical properties as a restoration material for URM structures is still limited. Therefore, other properties such as chemical interaction with the substrate, workability, thixotropic behavior, and aesthetic features of geopolymers need to be investigated for its wide application. The application method of geopolymer-based ECC as a strengthening material for a URM structure is by grouting injection. It is also worth recommending that other application techniques such as deep repointing, jacketing, and cement-plastering be explored.

Thermal, X-ray Diffraction and Oedometric Analyses of Silt-Waste/NaOH-Activated Metakaolin Geopolymer Composite

The present research investigates the possibility to create a silt-waste reinforced composite through a NaOH-activated, metakaolin-based geopolymerization process. In this regard, we used thermal exo–endo analysis, X-ray diffraction (XRD), and oedometric mechanical tests to characterize the produced composites. In our experimental conditions, the tested material mixtures presented exothermic peaks with maximum temperatures of about 100 °C during the studied geopolymerization process. In general, the XRD analyses showed the formation of amorphous components and new mineral phases of hydrated sodalite, natrite, thermonatrite and trona. From oedometric tests, we observed a different behavior of vertical deformation related to pressure (at RT) for the various produced composites. The present work indicated that the proposed geopolymerization process to recycle silt-waste produced composite materials with various and extended mineralogy and chemical–physical properties, largely depending on both the precursors and the specific alkaline-activating solution. Thermal analysis, XRD, and oedometric mechanical tests proved to be fundamental to characterize and understand the behavior of the newly formed composite material.

Thermally Treated Waste Silt as Filler in Geopolymer Cement

This study aims to investigate the feasibility of including silt, a by-product of limestone aggregate production, as a filler in geopolymer cement. Two separate phases were planned: The first phase aimed to determine the optimum calcination conditions of the waste silt obtained from Società Azionaria Prodotti Asfaltico Bituminosi Affini (S.A.P.A.B.A. s.r.l.). A Design of Experiment (DOE) was produced, and raw silt was calcined accordingly. Geopolymer cement mixtures were made with sodium or potassium alkali solutions and were tested for compressive strength and leaching. Higher calcination temperatures showed better compressive strength, regardless of liquid type. By considering the compressive strength, leaching, and X-ray diffraction (XRD) analysis, the optimum calcination temperature and time was selected as 750 °C for 2 h. The second phase focused on determining the optimum amount of silt (%) that could be used in a geopolymer cement mixture. The results suggested that the addition of about 55% of silt (total solid weight) as filler can improve the compressive strength of geopolymers made with Na or K liquid activators. Based on the leaching test, the cumulative concentrations of the released trace elements from the geopolymer specimens into the leachant were lower than the thresholds for European standards.

Influence of the Composition and Curing Time on Mechanical Properties of Fluidized Bed Combustion Fly Ash-Based Geopolymer

This paper presents novel research on a fluidized bed combustion (FBC) fly ash-based geopolymer as a contribution to the problem of FBC fly ash disposal, and a proposal for a new geopolymer composition-an environmentally friendly material that is possible to use in construction. Geopolymer samples of various composition (containing FBC fly ash as the main raw material, metakaolin and CRT glass as additional components, and sodium silicate and sodium hydroxide as activators) were subjected to flexural and compressive strength tests. An investigation on the effect of the demolding time was carried out on one selected mixture. The test showed that both the composition and the demolding time have a decisive influence on the basic mechanical properties. A mixture containing FBC fly ash to metakaolin in a mass ratio of 3:1, removed from the mold after 14 days, was found to be the best in terms of the mechanical parameters expected from a material that could be used in construction, e.g., for the production of precast elements. According to the results obtained, FBC fly ash is a promising and environmentally friendly raw material for the production of geopolymer, with good mechanical properties and low density. Moreover, a high compressive strength can be obtained by curing the geopolymer at ambient temperature.

A Review on Acoustic and Skid Resistance Solutions for Road Pavements

As cities grow in size, traffic also increases, thus making the population more exposed to road noise and traffic accidents. It is therefore important to study and understand which properties of the pavement influence its acoustic impact and skid resistance performance. The pavement texture plays a major role in generating noise and friction, and it can be engineered in order to control both of them at the same time. The phenomena regulating skid resistance are well understood today. The same applies for noise generation and propagation; the literature contains methods of designing the pavement surface layer to achieve consistent results. Several types of solutions can be found for asphalt mixtures, most of them derived from decades of studies and research. They use different approaches to be effective for noise and friction, but all have in common the control of the surface’s macro and microtexture. Finally, some considerations are made regarding novel paving solutions with artificial aggregates instead of natural ones to address noise and skid resistance.

Preliminary Evaluation of Geopolymer Mix Design Applying the Design of Experiments Method

The use of waste materials in road construction is becoming widely spread due to economic and environmental needs. Construction and demolition waste materials and mining residues have been studied for a long time. However, the use of fine materials, mainly from mine tailing and mining residue, is still complex, as they can be used as inert materials into the mix or can become a reactive agent in geopolymer mixes. In the present paper, an experimental application of basalt powder is proposed in the geopolymerisation reaction to produce artificial aggregates. In order to understand the input and output variables’ interactions used in the mix design, a statistical method called Design of Experiments was applied. With this design approach, it was possible to optimize the mix design of the experimental geopolymer mortars. The study evaluated several mixes with respect to their workability, compressive strength, and success rate of aggregates production. Finally, a model for predicting compressive strength is proposed and evaluated.

Preliminary Evaluation of Cement Mortars Containing Waste Silt Optimized with the Design of Experiments Method

Every year, up to 3 billion tons of non-renewable natural aggregates are demanded by the construction sector and approximately 623 million tons of waste (mining and quarrying) was produced in 2018. Global efforts have been made to reduce the number of virgin aggregates used for construction and infrastructure sectors. According to the revised waste framework directive in Europe, recycling at least 70% of construction and demolition waste materials by 2020 was obligatory for all member states. Nonetheless, quarries must work at full capacity to keep up with the demands, which has made quarry/mining waste management an important aspect during the past decades. Amongst the various recycling methods, quarry waste can be included in cement mortar mixtures. Thus, the current research focuses on producing cement mortars by partially substituting natural sand with the waste silt obtained from the limestone aggregate production in S.A.P.A.B.A. s.r.l. (Italy). A Design of Experiments (DOE) method is proposed to define the optimum mix design, aiming to include waste silt in cement mortar mixtures without affecting the final performance. Three cement mortar beams were produced and tested for each of the 49 randomized mixtures defined by the DOE method. The obtained results validate the design approach and suggest the possibility of substituting up to 20% of natural sand with waste silt in cement mortar mixtures.

Optimization of the Mix Formulation of Geopolymer Using Nickel-Laterite Mine Waste and Coal Fly Ash

Geopolymer cement has been popularly studied nowadays compared to ordinary Portland cement because it demonstrated superior environmental advantages due to its lower carbon emissions and waste material utilization. This paper focuses on the formulation of geopolymer cement from nickel–laterite mine waste (NMW) and coal fly ash (CFA) as geopolymer precursors, and sodium hydroxide (SH), and sodium silicate (SS) as alkali activators. Different mix formulations of raw materials are prepared to produce a geopolymer based on an I-optimal design and obtained different compressive strengths. A mixed formulation of 50% NMW and 50% CFA, SH-to-SS ratio of 0.5, and an activator-to-precursor ratio of 0.429 yielded the highest 28 d unconfined compressive strength (UCS) of 22.10 ± 5.40 MPa. Furthermore, using an optimized formulation of 50.12% NMW, SH-to-SS ratio of 0.516, and an activator-to-precursor ratio of 0.428, a UCS value of 36.30 ± 3.60 MPa was obtained. The result implies that the synthesized geopolymer material can be potentially used for concrete structures and pavers, pedestrian pavers, light traffic pavers, and plain concrete.