Innovative Fly Ash Geopolymer-Epoxy Composites: Preparation, Microstructure and Mechanical Properties

Technology for Automated Production of High-Performance Building Compounds for 3D Printing

Three-dimensional printing technology in construction is a rapidly growing field that offers innovative opportunities for design and construction execution. A key component of this process is the automated production of high-performance construction mixtures that meet specific requirements for strength, fluidity, and setting speed. This overview article outlines the history and development of 3D printing technology in the construction industry, describes various printing technologies, and discusses the properties and requirements for construction mixes. Special attention is given to automated systems for batching and mixing ingredients, which increase the precision and efficiency of production. The different types of construction mixes used in 3D printing and the main technical and operational challenges associated with their application are also presented. The article's conclusions highlight the potential of this technology to revolutionize the construction industry by improving efficiency and reducing costs and project lead times.

Amine Infused Fly Ash Grafted Acrylic Acid/Acrylamide Hydrogel for Carbon Dioxide (CO2) Adsorption and Its Kinetic Analysis

In most carbon dioxide (CO2) capture processes, chemical absorption using an amine solvent is widely used technology; however, the solvent is prone to solvent degradation and solvent loss which leads to the formation of corrosion. This paper investigates the adsorption performance of amine-infused hydrogels (AIFHs) to increase carbon dioxide (CO2) capture by leveraging the potency of amine absorption and adsorption properties of class F fly ash (FA). The solution polymerization method was used to synthesize the FA-grafted acrylic acid/acrylamide hydrogel (FA-AAc/AAm), which was then immersed in monoethanolamine (MEA) to form amine infused hydrogels (AIHs). The prepared FA-AAc/AAm showed dense matrices morphology with no obvious pore at the dry state but capable of capturing up to 0.71 mol/g CO2 at 0.5 wt% FA content, 2 bar pressure, 30 °C reaction temperature, 60 L/min flow rate, and 30 wt% MEA contents. Cumulative adsorption capacity was calculated and Pseudo-first order kinetic model was used to investigate the CO2 adsorption kinetic at different parameters. Remarkably, this FA-AAc/AAm hydrogel is also capable of absorbing liquid activator that was 1000% more than its original weight. FA-AAc/AAm can be used as an alternative AIHs that employ FA waste to capture CO2 and minimize the GHG impact on the environment.

Study of Geopolymer Composites Based on Volcanic Ash, Fly Ash, Pozzolan, Metakaolin and Mining Tailing

This work studies the feasibility to employ a combination of volcanic ash (natural waste) with different raw materials in the production of geopolymers: fly ash and mining tailing (considered hazardous solid waste), natural pozzolan, and metakaolin. This study compares the properties of geopolymers based on volcanic ash with fly ash, pozzolan, metakaolin, and mining tailing in a relation of 1:1 with the addition of NaOH 15M and Na2SiO3 as alkali activators. FTIR and XRD assays and mechanical tests were employed to characterize the geopolymers. The results showed that those materials can be used as raw materials to produce geopolymers. Additionally, the results revealed that prime material composition and their mineralogical characteristics influence the geopolymerization reaction and compression strength, reaching values of 35 MPa for the volcanic ash-pozzolan mixture. The pozzolan is a good source of Al2O3 and SiO2 and is highly reactive to the alkali activators resulting in a better geopolymerization in comparison to the mixtures of volcanic ash with metakaolin, fly ash, or mining tailing.

Strength and durability performance of geopolymer binder of ambient cured alkali-activated MSW rejected waste and GGBFS mixes

Municipal solid waste (MSW) is being generated every day, and its safe disposal is one of the major environmental challenges nowadays. The main focus of this research is to examine the usability of the soil-like inorganic component of MSW, named MSW rejected waste, as a geopolymer binder. In this study, the effect of mutual replacement of MSW rejected waste with ground granulated blast furnace slag (GGBFS) at 10% interval on the synthesis of geopolymer binder with reference to density, alkali concentration, and curing period is studied by conducting compressive strength, permeability, and durability tests. The design of mixes follows, according to their pre-determined compaction parameters, optimum moisture content, and maximum dry density. The curing conditions were found to be significant in affecting the properties of the geopolymer. The effect of acid environment on strength properties of geopolymer mixes has also been studied. The unconfined compressive strength, pulse wave velocity, water absorption, and microstructural analysis have been performed on designed mixes to identify the optimized design of the mixtures. Results showed that the strength increased with the increment of GGBFS percentage and increment of concentration of sodium hydroxide (NaOH) up to 8 M.

The Effect of Different Modifying Methods on Physical, Mechanical and Thermal Performance of Cellular Geopolymers as Thermal Insulation Materials for Building Structures

Geopolymers represent a new class of inorganic materials that have great potential for practical application due to the properties of used raw materials, as well as the peculiarities of the cementitious matrix structure formed during the geopolymerization process. Cellular geopolymer specimens were produced in this study using class F fly ash product, which is characterized by low reactivity during geopolymerization. Several standard methods, as well as microstructural studies were applied to evaluate the effect of the following factors on the physical-mechanical and thermophysical characteristics of cellular geopolymers: the use of various mineral modifying components for synthesis of geopolymer systems; high-temperature treatment; the introduction method of alkaline activator. It was observed that “ageing” an aqueous alkali solution for 24 h before mixing with fly ash and foam agent was able to provide a boost of compressive strength of cellular geopolymer specimens up to about 2.5 times, while decreasing the average density by about 28% for all experimental mixes, except for PC-modified mixes. Additionally, high-temperature treatment at 600 °C enables an enhanced strengthening effect of pore structure in cellular geopolymer matrix up to 1.5 times. This phenomenon is especially pronounced for the mixes with 24 h “aged” alkaline solution with exception for PC-modified mixes; for those, high-temperature treatment at 600 °C leads to strength decrease up to 40%. The introduction method of alkaline activator and high-temperature treatment showed a controversial effect on thermal conductivity coefficient depending on the mineral modifying component used for the synthesis of cellular geopolymers. The proposed method for calculation of total porosity of cellular structure of geopolymers as a polycomponent material demonstrated a high degree of correlation with the R2 value of at least 0.96 between the average density and the calculated total porosity. However, a low degree of correlation with R2 not exceeding 0.29 was observed for the measured nanoporosity, regardless of the introduction method of alkaline activator and high-temperature treatment.

Performance of Fly Ash-Based Inorganic Polymer Mortar with Petroleum Sludge Ash

Petroleum sludge is a waste product resulting from petroleum industries and it is a major source of environmental pollution. Therefore, developing strategies aimed at reducing its environmental impact and enhance cleaner production are crucial for environmental mortar. Response surface methodology (RSM) was used in designing the experimental work. The variables considered were the amount of petroleum sludge ash (PSA) in weight percent and the ratio of sodium silicate to sodium hydroxide, while the concentration of sodium hydroxide was kept constant in the production of geopolymer mortar cured at a temperature of 60 °C for 20 h. The effects of PSA on density, compressive strength, flexural strength, water absorption, drying shrinkage, morphology, and pore size distribution were investigated. The addition of PSA in the mortar enhanced the mechanical properties significantly at an early age and 28 days of curing. Thus, PSA could be used as a precursor material in the production of geopolymer mortar for green construction sustainability. This study aimed to investigate the influence of PSA in geopolymer mortar.

Long-Term Physical and Mechanical Properties and Microstructures of Fly-Ash-Based Geopolymer Composite Incorporating Carbide Slag

The long-term property development of fly ash (FA)-based geopolymer (FA–GEO) incorporating industrial solid waste carbide slag (CS) for up to 360 d is still unclear. The objective of this study was to investigate the fresh, physical, and mechanical properties and microstructures of FA–GEO composites with CS and to evaluate the effects of CS when the composites were cured for 360 d. FA–GEO composites with CS were manufactured using FA (as an aluminosilicate precursor), CS (as a calcium additive), NaOH solution (as an alkali activator), and standard sand (as a fine aggregate). The fresh property and long-term physical properties were measured, including fluidity, bulk density, porosity, and drying shrinkage. The flexural and compressive strengths at 60 d and 360 d were tested. Furthermore, the microstructures and gel products were characterized by scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS). The results show that the additional 20.0% CS reduces the fluidity and increases the conductivity of FA–GEO composites. Bulk densities were decreased, porosities were increased, and drying shrinkages were decreased as the CS content was increased from 0.0% to 20.0% at 360 d. Room temperature is a better curing condition to obtain a higher long-term mechanical strength. The addition of 20.0% CS is more beneficial to the improvement of long-term flexural strength and toughness at room temperature. The gel products in CS–FA–GEO with 20.0% CS are mainly determined as the mixtures of sodium aluminosilicate (N–A–S–H) gel and calcium silicate hydration (C–S–H) gel, besides the surficial pan-alkali. The research results provide an experimental basis for the reuse of CS in various scenarios.

Alkali-Activated Mortars Modified by Epoxy-Carbon Fiber Composites Wastes

Short chopped fibers coated by epoxy resin of different length (5 to 10 mm length) were added at low volume content (about 4.6% on the composite) to alkali-activated fly ash or metakaolin mortars. These uncured scraps derive from the production of carbon fiber-reinforced polymer composites and they are not presently recycled, despite their outstanding mechanical properties. The workability, microstructure, porosity, and physical and mechanical properties (mainly flexural strength) of the derived materials were investigated. Superior flexural strength and increased toughness were obtained. An acid treatment of the scraps further improved the mechanical properties of the mortars by changing the chemical structure of the surface, thus increasing the interaction with the inorganic phase. These results foster the use of these wastes to improve the performance of low carbon footprint building materials such as alkali-activated composites in the building industry.

The Effects of Nanosilica on Mechanical Properties and Fracture Toughness of Geopolymer Cement

Nanosilica produced from physically-processed white rice husk ash agricultural waste can be incorporated into geopolymer cement-based materials to improve the mechanical and micro performance. This study aimed to investigate the effect of natural nanosilica on the mechanical properties and microstructure of geopolymer cement. It examined the mechanical behavior of geopolymer paste reinforced with 2, 3, and 4 wt% nanosilica. The tests of compressive strength, direct tensile strength, three bending tests, Scanning Electron Microscope-Energy Dispersive X-ray (SEM/EDX), X-ray Diffraction (XRD), and Fourier-transform Infrared Spectroscopy (FTIR) were undertaken to evaluate the effect of nanosilica addition to the geopolymer paste. The addition of 2 wt% nanosilica in the geopolymer paste increased the compressive strength by 22%, flexural strength by 82%, and fracture toughness by 82% but decreased the direct tensile strength by 31%. The microstructure analysis using SEM, XRD, and FTIR showed the formation of calcium alumina-silicate hydrate (C-A-S-H) gel. The SEM images also revealed a compact and cohesive geopolymer matrix, indicating that the mechanical properties of geopolymers with 2 wt% nanosilica were improved. Thus, it is feasible for nanosilica to be used as a binder.

Supramolecular aggregation of colloidal natural organic matter masks priority pollutants released in water from peat soil

Natural organic matter (NOM) from Sphagnum peat soil is extracted in water and subjected to several investigations to obtain structural and conformational information. Data show that the extracted NOM is self-organized in colloidal aggregates of variable sizes (from nano to micro scales, depending on the solvent composition, i.e., ultrapure water, solutions with denaturing agents, acetone, ethanol). Aggregates are formed by highly heterogeneous classes of organic compounds. According to the results of nuclear magnetic resonance and fluorescence measurements, the three-dimensional structure of aggregates, revealed by scanning electron microscope imaging, is supposed to be stabilized by the exposition of polar functional groups to the solvent, with consequent formation of hydrogen bonds, dipole-interactions and cation bridging. In contrast, the inner part of the aggregates displays hydrophobic features and is hypothesized to be further reinforced by the establishment of π-stacking interactions. The structure is assumed to be a supramolecular aggregation of small-medium oligomeric fragments (Max 750 Da) in which priority pollutants are entrapped by dispersive forces. The structures are shown to be nanosized spheroidal particles further aggregated to form higher dimension supra-structures. Carbohydrates play primary role, stabilizing the structure and giving marked hydrophilic properties to the aggregates.

Properties of a New Insulation Material Glass Bubble in Geo-Polymer Concrete

This paper details analytical research results into a novel geopolymer concrete embedded with glass bubble as its thermal insulating material, fly ash as its precursor material, and a combination of sodium hydroxide (NaOH) and sodium silicate (Na₂SiO₃) as its alkaline activator to form a geopolymer system. The workability, density, compressive strength (per curing days), and water absorption of the sample loaded at 10% glass bubble (loading level determined to satisfy the minimum strength requirement of a load-bearing structure) were 70 mm, 2165 kg/m³, 52.58 MPa (28 days), 54.92 MPa (60 days), and 65.25 MPa (90 days), and 3.73 %, respectively. The thermal conductivity for geopolymer concrete decreased from 1.47 to 1.19 W/mK, while the thermal diffusivity decreased from 1.88 to 1.02 mm²/s due to increased specific heat from 0.96 to 1.73 MJ/m³K. The improved physicomechanical and thermal (insulating) properties resulting from embedding a glass bubble as an insulating material into geopolymer concrete resulted in a viable composite for use in the construction industry.

Resistance of Soda Residue-Fly Ash Based Geopolymer Mortar to Acid and Sulfate Environments

The early mechanical performances of low-calcium fly ash (FFA)-based geopolymer (FFA-GEO) mortar can be enhanced by soda residue (SR). However, the resistance of SR-FFA-GEO mortar to acid or sulfate environments is unclear, owing to the various inorganic calcium salts in SR. The aim of this study was to investigate the long-term mechanical strengths of up to 360 d and evaluate the resistance of SR-FFA-GEO mortar to 5% HCl and 5% Na₂SO₄ environments through the losses in compressive strength and mass. Scanning Electron Microscopy (SEM), Energy-Dispersive Spectroscopy (EDS) and Fourier Transform Infrared Spectrometer (FTIR) experiments were conducted for the SR-FFA-GEO mortars, both before and after chemical attack, to clarify the attack mechanism. The results show that the resistances of the SR-FFA-GEO mortar with 20% SR (namely M10) to 5% HCl and 5% Na₂SO₄ environments are superior to those of cement mortar. The environmental HCl reacts with the calcites in SR to produce CaCl₂, CO₂ and H₂O to form more pores under HCl attack, and the environmental Na⁺ cations from Na₂SO₄ go into Si-O-Al network structure, to further enhance the strength of mortar under Na₂SO₄ attack. These results provide the experimental basis for the durability optimization of SR-FFA-GEO mortars.

Fibre-Reinforced Geopolymer Concretes for Sensible Heat Thermal Energy Storage: Simulations and Environmental Impact

Power plants based on solar energy are spreading to accomplish the incoming green energy transition. Besides, affordable high-temperature sensible heat thermal energy storage (SHTES) is required. In this work, the temperature distribution and thermal performance of novel solid media for SHTES are investigated by finite element method (FEM) modelling. A geopolymer, with/without fibre reinforcement, is simulated during a transient charging/discharging cycle. A life cycle assessment (LCA) analysis is also carried out to investigate the environmental impact and sustainability of the proposed materials, analysing the embodied energy, the transport, and the production process. A Multi-Criteria Decision Making (MCDM) with the Analytical Hierarchy Process (AHP) approach, taking into account thermal/environmental performance, is used to select the most suitable material. The results show that the localized reinforcement with fibres increases thermal storage performance, depending on the type of fibre, creating curvatures in the temperature profile and accelerating the charge/discharge. High-strength, high-conductivity carbon fibres performed well, and the simulation approach can be applied to any fibre arrangement/material. On the contrary, the benefit of the fibres is not straightforward according to the three different scenarios developed for the LCA and MCDM analyses, due to the high impact of the fibre production processes. More investigations are needed to balance and optimize the coupling of the fibre material and the solid medium to obtain high thermal performance and low impacts.

Hybrid Fly Ash-Based Geopolymeric Foams: Microstructural, Thermal and Mechanical Properties

This research investigates the preparation and characterization of new organic–inorganic geopolymeric foams obtained by simultaneously reacting coal fly ash and an alkali silicate solution with polysiloxane oligomers. Foaming was realized in situ using Si⁰ as a blowing agent. Samples with density ranging from 0.3 to 0.7 g/cm³ that show good mechanical properties (with compressive strength up to ≈5 MPa for a density of 0.7 g/cm³) along with thermal performances (λ = 0.145 ± 0.001 W/m·K for the foamed sample with density 0.330 g/cm³) comparable to commercial lightweight materials used in the field of thermal insulation were prepared. Since these foams were obtained by valorizing waste byproducts, they could be considered as low environmental impact materials and, hence, with promising perspectives towards the circular economy.

Hybrid Geopolymeric Foams for the Removal of Metallic Ions from Aqueous Waste Solutions

For the first time, hybrid organic–inorganic geopolymeric foams were successfully used as monolithic adsorbents for the removal of metallic ions pollutants from wastewaters. The foams were realized by the in situ foaming of a hybrid geopolymer obtained by a reaction of metakaolin and polysiloxane oligomers under strong alkaline conditions and then cured at room temperature. In this way, porous materials with densities ranging from 0.4 to 0.7 g/cm³ and showing good mechanical properties were produced. With the aim of producing self-standing monolithic adsorbents for the removal of metallic ions pollutants from wastewaters, these porous hybrid geopolymers were subjected to a washing pretreatment with ultrapure water, dried, and then used for absorption tests by dipping them into an aqueous solution with an initial concentration of 20 ppm of Pb²⁺, Cd²⁺, Cu²⁺, and Zn²⁺ ions. Preliminary results indicated that all the tested materials are effective in the adsorption of the tested metal ions and do not release the removed metal ions upon sinking in ultrapure water, even for a very long time. Interestingly, compressive strength tests performed before and after the washing treatments show that the foamed samples remain intact and maintain their physical–mechanical characteristics, suggesting that these kinds of materials are promising candidates for the production of self-standing, monolithic adsorbent substrates that can be easily collected when exhausted, which is a major advantage in comparison with the use of powdered adsorbents. Moreover, since these materials can be obtained by a simple and versatile experimental procedure, they could be easily shaped or directly foamed into precast molds to be used in packed beds as membranes.

Hybrid Geopolymers from Fly Ash and Polysiloxanes

The preparation and characterization of innovative organic-inorganic hybrid geopolymers, obtained by valorizing coal fly ash generated from thermoelectric power plants, is reported for the first time. These hybrid materials are prepared by simultaneously reacting fly ash and dimethylsiloxane oligomers at 25 °C in a strongly alkaline environment. Despite their lower density, the obtained materials are characterized by highly improved mechanical properties when compared to the unmodified geopolymer obtained without the use of polysiloxanes, hence confirming the effectiveness of the applied synthetic strategy which specifically aims at obtaining hybrid materials with better mechanical properties in respect to conventional ones. This study is an example of the production of new materials by reusing and valorizing waste raw resources and by-products, thus representing a possible contribution towards the circular economy.

Stabilization of Loess Using Nano-SiO₂

Improving the performance of loess is of significant importance for lowering its collapsibility and water sensitivity to construction requirements and for geohazard mitigation. The present paper studies the changes in mechanical, structural, and mineralogical properties of nano-SiO₂-treated loess with different contents and curing days. The mechanical behavior was examined by unconfined compressive strength (UCS) of untreated and treated loess. To better understand the mechanisms of stabilization, particle size distributions, scanning electron microscope (SEM) images, and X-ray diffraction (XRD) analyses were carried out. The results show that the UCS increase with increasing contents and curing days due to nano-SiO₂ addition produced coarser particles, denser packing, and smaller pores in treated loess. The changes in the properties can be attributed to the formation of aggregation and agglomeration, with greater particle sizes and more interparticle contact. In addition, the results from mineralogical component analysis further confirm that physical structure modification controls the changes in mechanical and fabric properties, rather than chemical component alteration. Even small nano-SiO₂ additions can also provide great improvement when curing days are enough for the treated loess. These findings reveal that nano-SiO₂ has the potential to serve as a cost-effective stabilized additive that treats the universal loess.

Short-Term Behavior of Slag Concretes Exposed to a Real In Situ Mediterranean Climate Environment

At present, one of the most suitable ways to get a more sustainable cement industry is to reduce the CO₂ emissions generated during cement production. In order to reach that goal, the use of ground granulated blast-furnace slag as clinker replacement is becoming increasingly popular. Although the effects of this addition in the properties of cementitious materials are influenced by their hardening conditions, there are not too many experimental studies in which slag concretes have been exposed to real in situ environments. Then, the main objective of this research is to study the short-term effects of exposure to real Mediterranean climate environment of an urban site, where the action of airborne chlorides from sea water and the presence of CO₂ are combined, in the microstructure and service properties of a commercial slag cement concrete, compared to ordinary Portland cement (OPC). The microstructure was studied with mercury intrusion porosimetry. The effective porosity, capillary suction coefficient, chloride migration coefficient, carbonation front depth, and compressive strength were also analyzed. Considering the results obtained, slag concretes exposed to a real in situ Mediterranean climate environment show good service properties in the short-term (180 days), in comparison with OPC.