The key objective of this study was to develop marble-based geopolymer concrete and examine the viability of its application as a sustainable structural material for the construction industry. The results of the research demonstrated that marble-based geopolymer concrete can be developed, and its physical/mechanical properties were shown to have a very good performance. According to various experimental tests and a large-scale ready-mixed plant test, it was found that the marble-based geopolymer concrete displayed a good workability and was not easily influenced by temperature changes. The results showed that marble-based geopolymer concrete has an excellent potential for further engineering development in the future.

The basic oxygen furnace slag is a major waste by-product generated from steel-producing plants. It possesses excellent characteristics and can be used as a natural aggregate. Chemically, the basic oxygen furnace slag encloses free CaO and free MgO, which is the main reason for the expansion crisis since these free oxides of alkaline earth metals react with water to form their hydroxide yields. The objective of the present research study is to stabilize the basic oxygen furnace slag by using innovative geopolymer technology, as their matrix contains a vast quantity of free silicon, which can react with free CaO and free MgO to form stable silicate compounds resulting in the prevention of the basic oxygen furnace slag expansion predicament. Lab-scale and ready-mixed plant pilot-scale experimental findings revealed that the compressive strength of fine basic oxygen furnace slag-based geopolymer mortar can achieve a compressive strength of 30–40 MPa after 28 days, and increased compressive strength, as well as the expansion, can be controlled less than 0.5% after ASTM C151 autoclave testing. Several pilot-scale cubic meters basic oxygen furnace slag-based geopolymer concrete blocks were developed in a ready-mixed plant. The compressive strength and autoclave expansion test results demonstrated that geopolymer technology does not merely stabilize the basic oxygen furnace slag production issue totally, but also turns the slags into value-added products.

Geopolymers (GPs) are gaining prominence due to their low carbon emissions and sustainable attributes. However, one challenge with GPs, particularly those made with ground granulated blast furnace slag (GGBFS), is their significant shrinkage during the geopolymerization process, limiting its practical applicability. This study focuses on how the substitution ratio of metakaolin (MK) and the concentration of sodium hydroxide (NaOH) in the activator can influence the shrinkage and strength of a GGBFS-based GP. The experimental approach employed a 3 × 3 parameter matrix, which varied MK substitution ratios (0%, 50%, and 100%) and adjusted the NaOH concentration (6 M, 10 M, and 14 M). The results revealed that increasing MK substitution, particularly with 6 M NaOH activation, reduced the GP shrinkage but also diminished compressive strength, requiring higher NaOH concentrations for strength improvement. Statistical tools, including analysis of variance (ANOVA) and second-order response surface methodology (RSM), were employed for analysis. ANOVA results indicated the significant impacts of both the MK content and NaOH concentration on compressive strength, with no observable interaction. However, the shrinkage exhibited a clear interaction between MK content and NaOH concentration. The RSM model accurately predicted compressive strength and shrinkage, demonstrating a high predictive accuracy, for which the coefficients of determination (R²) were 0.99 and 0.98, respectively. The model provides a reliable method for determining the necessary compressive strength and shrinkage for GGBFS-based GP based on MK substitution and NaOH concentration. Within the optimization range, the RSM model compared with experimental results showed a 6.04% error in compressive strength and 0.77% error in shrinkage for one interpolated parameter set. This study establishes an optimized parameter range ensuring a GP performance that is comparable to or surpassing OPC, with a parameter set achieving a compressive strength of 34.9 MPa and shrinkage of 0.287% at 28 days.

The aim of this study is to assess the process of synthesizing potassium-based geopolymers (KGL) into leucite ceramics with regard to five variables, namely, alkaline solution ratio (R), sintering time (S), calcining temperature (T), mixing time (M), and curing time (C). Under these conditions, the specimens were tested by the viscosity test, the mechanical properties test, X-ray diffraction (XRD), Fourier-transform infrared (FTIR) spectroscopy, and scanning electron microscopy (SEM) to understand the geopolymerization reactions and the characteristics of the KGL network. The results indicate that a KOH to K₂O/SiO₂ ratio of 1:1 promotes the reaction within metakaolin. XRD analysis of the KGL shows that, when the temperature is 1100 °C, the phase transforms into the leucite phase. Moreover, XRD analysis, mechanical properties, and FTIR all indicate improved characteristics when the curing time increases from 1 to 8 h. This might be attributed to the enhancement of the strong interaction between the matrix and the alkaline solution upon achieving adequate time to complete the geopolymerization process and forming a more stable three-dimensional structure. The formulation which formed the purest leucite phase consisted of: a 1:1 alkaline solution ratio, 10 min mixing time, 8 h curing time, 1200 °C calcining temperature, and 2 h sintering time.