The setting behavior of geopolymers is affected by the type of source materials, alkali activators, mix formulations, and curing conditions. Calcium hydroxide is known to be an effective additive to shorten the setting period of geopolymers. However, there is still room for improvement in the understanding of the effect of calcium hydroxide on the setting and phase evolution of geopolymers. In this study, the setting behavior and phase evolution of geopolymer containing calcium hydroxide were investigated by XRD analysis. The setting time of the geopolymer was inconsistently shortened as the amount of calcium hydroxide increased. A low calcium hydroxide dose of up to 2% of the total mix weight could contribute to the enhancement of compressive strength of geopolymers besides a fast-setting effect. The C-S-H gel is rapidly precipitated at the early stage of reaction in geopolymers containing high calcium hydroxide with some of the calcium hydroxide remaining intact. The ex-situ high-temperature XRD analysis and Rietveld refinement results revealed that geopolymer and C-S-H gel transformed into Si-rich nepheline and wollastonite, respectively. The wollastonite was also observed in heat-treated geopolymers with a low calcium hydroxide dose. It is believed that C-S-H gel can be precipitated along with geopolymers regardless of how much calcium hydroxide is added.

Geopolymer is a synthetic amorphous aluminosilicate material that can be used as an inorganic binder to replace ordinary Portland cement. Geopolymer is produced by mixing aluminosilicate source materials with alkali activators and curing the mixture either at ambient or low temperatures. Geopolymer research for lunar-based construction is actively underway to enable astronauts to stay on the moon for long periods. This research has been spurred on by earnest discussions of in situ resource utilization (ISRU). Recent research shows that the lunar regolith simulant-based geopolymers have high application potential to protect astronauts from the harsh moon environment. However, not all the simulants perfectly reproduce the lunar regolith, and the characteristics of the lunar regolith vary depending on the site. Issues remain regarding the applicability of geopolymer technology to contribute to ISRU through an elaborate and systematic plan of experiments. In this paper, the potential of geopolymers is assessed as a lunar-based construction material with the latest research results. Future work to develop the lunar regolith-based geopolymer technology is also proposed.

There is no standardized procedure for producing geopolymers; therefore, many researchers develop their own procedures for mixing and curing to achieve good workability and strength development. The curing scheme adopted is important in achieving maximum performance of resultant geopolymers. In this study, we evaluated the impact of sealed and unsealed curing on mechanical strength of geopolymers. Fly ash-based geopolymers cured in sealed and unsealed moulds clearly revealed that retention of water during curing resulted in superior strength development. The average compressive strength of sealed-cured geopolymers measured after 1 day of curing was a modest 50 MPa, while after 7 day curing the average compressive strength increased to 120~135 MPa. In the unsealed specimens the average compressive strength of geopolymers was lower; ranging from 60 to 90 MPa with a slight increase as the curing period increased. Microcracking caused by dehydration is postulated to cause the strength decrease in the unsealed cured samples. These results show that water is a crucial component for the evolution of high strength three-dimensional cross-linked networks in geopolymers.

Superplasticizers (cement concrete water reducers) are applied to improve the flowability of calcium-rich, alkali-activated materials, with inconsistent results. However, superplasticizer applications are limited in metakaolin-based geopolymers. The possibility of using polycarboxylate superplasticizers and methyl isobutyl carbinol (MIBC) to ameliorate the flowability of metakaolin-based geopolymers was investigated. The ratio of metakaolin, fumed silica, NaOH or KOH, and water in geopolymers at a Na₂O or K₂O:Al₂O₃:SiO₂:H₂O ratio = 1:1:4:10 or 1:1:4:11 was maintained in the formulations. In this study, ether- or ester-based polycarboxylate superplasticizers did not improve the workability of fresh metakaolin-based Na-geopolymers. A low MIBC dose (0.5 wt.% of metakaolin) improved the flowability by 19% and additionally increased the 7-day compressive strength by 22% from 68 to 83 MPa for plain Na-geopolymers. The entrained fine froths produced by adding MIBC during mixing likely reduced friction between metakaolin particles, and the slurry became more workable. Hence, the geopolymer mixture with an improved flowability became more homogenous, which ensured more extensive metakaolin dissolution and hydrolysis. A low MIBC dose could be effective for Na-geopolymers with dual benefits of improved workability and enhanced compressive strength.

Pond ash is a mixture of mostly coarser fly ash and bottom ash. The recycling rate of pond ash is low because pond ash is mixed with seawater and deposited in ponds. The pond ash is also subjected to natural weathering over a period of time. In this study, we investigated whether pond ash can be used as a raw material of geopolymers, without any purification process or through a minimal purification process. In addition, we investigated whether synthetic basalt made by adding foaming agent to geopolymer or casting it into a mold can show the surface of the natural basalt as it is. The highest 7-day compressive strength in geopolymers from pond ash without purification process was 26 MPa. The highest 7-day compressive strength in geopolymers from pond ash with impurities removed through dry sieve analysis was found to improve to 80 MPa. On the other hand, synthetic basalt made with geopolymer was shown to be more advantageous aesthetically when produced by casting it in a silicone mold rather than by adding a foaming agent. Non-purified pond ash can be made into geopolymers having low strength. Pond ash purified by sieving can, without use of an aggregate, be made into geopolymer having high-strength. Also, it is possible to produce synthetic basalt with the same appearance as natural basalt and sufficient strength for commercialization. This process will contribute to the mass consumption and recycling of pond ash.