The article presents preliminary results in studying reinforced and light-weight geopolymers, which can be employed in buildings, especially for walling. Such materials are very promising for the construction industry having great potential due to their favorable properties such as high mechanical strengths, low thermal conductivity, and low density. Moreover, they also exhibit several advantages from an economic and ecological point of view. The present study exanimated the use of specific fillers for the metakaolin-based light-weight geopolymers, emphasizing the above-mentioned physical properties. This research also investigated the electromagnetic shielding ability of the carbon grid built into the light-weight geopolymer structure. According to the study, the most suitable materials to be used as fillers are polystyrenes, along with hollow ceramic microsphere and Liapor. The polystyrene geopolymer (GPP) achieves five times lower thermal conductivity compared to cement concretes, which means five times lower heat loss by conduction. Furthermore, GPP is 28% lighter than the standard geopolymer composite. Although the achieved flexural strength of GPP is high enough, the compressive strength of GPP is only 12 MPa. This can be seen as a compromise of using polystyrene as a filler. At the same time, the results indicate that Liapor and hollow ceramic microsphere are also suitable fillers. They led to better mechanical strengths of geopolymer composites but also heavier and higher thermal conductivity compared to GPP. The results further show that the carbon grid not only enhances the mechanical performances of the geopolymer composites but also reduces the electromagnetic field. Carbon grids with grid sizes of 10 mm × 15 mm and 21 mm × 21 mm can reduce around 60% of the Wi-Fi emissions when 2 m away from the signal transmitter. Moreover, the Wi-Fi emission was blocked when the signal transmitter was at a distance of 6 m.

The article deals with the investigation of geopolymer foams (GFs) synthesized using by-products coming from the (i) screening-, (iv) pyrolysis-, (iii) dust abatement- and (iv) fusion-processes of the secondary aluminum industry. Based on principles of the circular economy to produce new technological materials, the experimental study involves industrial by-products management through the recovery, chemical neutralization, and incorporation of these relatively hazardous waste into the GFs. The geopolymeric matrix, consisting of metakaolin (MK) and silica sand (SA) with a 1:1 wt.% ratio, and chopped carbon fibers (CFs, 1 wt.% MK), was doped with the addition of different aluminum-rich industrial by-products with a percentage from 1 to 10 wt.% MK. The gas (mainly hydrogen) produced during the chemical neutralization of the by-products represents the foaming agents trapped in the geopolymeric structure. Several experimental tests were carried out to characterize the mechanical (flexural, compressive, and Charpy impact strengths) and thermal properties (thermal conductivity, and diffusivity, and specific heat) of the GFs. Results identify GFs with good mechanical and thermal insulation properties, encouraging future researchers to find the best combination (for types and proportions) of the different by-products of the secondary aluminum industry to produce lightweight geopolymer foams. The reuse of these industrial by-products, which according to European Regulations cannot be disposed of in the landfill, also brings together environmental sustainability and safe management of hazardous material in workplaces addressed to the development of new materials.

The paper presents the results of research concerning the influence of a metallic micromaterial on the thermal conductivity λ, specific heat Cp, and thermal diffusivity a of modified geopolymers. Iron oxide in the form of powder with an average granulation of 10 μm was used as the geopolymer-modifying material. The research concerned geopolymer composite samples with metakaolin (activated with potassium silicate) and the addition of iron in amounts ranging from 0.5% to 2.5% in relation to the weight of the metakaolin. Additionally, the samples were modified with sand and fireclay in two different amounts—1:1 and 1:1.2 in relation to the metakaolin. The addition of fireclay caused a decrease in the thermal conductivity of the composites by 30% when compared to the samples with the addition of sand. The lowest value of the thermal conductivity coefficient λ was obtained for the geopolymer with metakaolin and fireclay. When the ratio of these components in the composite was 1:1, the value of thermal conductivity was equal to 0.6413 W/(m·K), while in the case of their ratio being 1:1.2, it was equal to 0.6456 W/(m·K). In the samples containing fireclay, no significant influence of the added iron on the values of thermal conductivity was noticed. In the case of the geopolymer with sand, the effect was noticeable, and it was most visible in the samples containing metakaolin and sand in the ratio of 1:1.2. It was noticed that with an increase in the addition of Fe, the thermal conductivity of the composite increased.

Geopolymer foams are excellent materials in terms of mechanical loads and fire resistance applications. This study investigated the foaming process of geopolymers and foam stability, with a focus on the fire resistance performance when using polystyrene as the base layer. The main purpose is to define the influence of porosity on the physical properties and consequently to find applications and effectiveness of geopolymers. In this study, lightweight materials are obtained through a process called geopolymerization. Foaming was done by adding aluminum powder at the end of the geopolymer mortar preparation. The interaction between the aluminum powder and the alkaline solution (used for the binder during the mixing process) at room temperature is reactive enough to develop hydrogen-rich bubbles that increase the viscosity and promote the consolidation of geopolymers. The basic principle of thermodynamic reactions responsible for the formation of foams is characterized by hydrogen-rich gas generation, which is then trapped in the molecular structure of geopolymers. The geopolymer foams in this study are highly porous and robust materials. Moreover, the porosity distribution is very homogeneous. Experimental assessments were performed on four specimens to determine the density, porosity, mechanical strength, and thermal conductivity. The results showed that our geopolymer foams layered on polystyrene boards (with optimal thickness) have the highest fire resistance performance among others. This combination could withstand temperatures of up to 800 °C for more than 15 min without the temperature rising on the insulated side. Results of the best-performing geopolymer foam underline the technical characteristics of the material, with an average apparent density of 1 g/cm³, a volume porosity of 55%, a thermal conductivity of 0.25 W/mK, and excellent fire resistance.

This study examines the impact of calcium-rich fly ash as an additive on metakaolin-based geopolymers. Six types of fly ash (FA1-FA7) from different thermal power plants in the Czech Republic were collected and characterized based on their physical and chemical properties. The addition of fly ash into the geopolymers was evaluated through a multicriteria assessment that focused on density and mechanical properties. By using a multi-criteria approach, the assessment provides a comprehensive and holistic evaluation of the material, allowing for a more informed decision about the optimal addition of additives. This approach helps to minimize any negative impact on the material’s properties while maximizing the utilization of the by-product. The result is an optimized geopolymer mixture with improved properties and increased sustainability, as the by-product is used beneficially. Furthermore, calcium content is the key factor that affects the physical properties of geopolymers by accelerating the curing time. This rapid process can result in reduced strength with increasing fly ash content. The multicriteria assessment revealed that the optimal condition is achieved using fly ash (FA2) from the Loucovice thermal power plant (5.2 wt.% Ca) that was treated at a temperature of 615 °C. The flexural strength of FA2-based geopolymers increased by 13% compared to concrete (standard). However, the addition of fly ash significantly reduced the compressive strength of geopolymers throughout the range of specimens. The Charpy impact strength of FA2 was higher than the standard due to the presence of unburned biomass solids in the ash structure that can absorb energy easily.

In the framework of the industry of secondary aluminum, the chemical neutralization of highly reactive materials that come from the pre-treatment screening processes of scraps (beverage cans and domestic appliances) was investigated through experiments in aqueous alkaline solutions. Metallic aluminum-rich by-products are classified, according to EU law, as dangerous waste, as they can potentially develop flammable gases capable of forming explosive mixtures with air. In this way they cannot be disposed of in landfills for non-hazardous wastes if chemical neutralization is not planned and performed beforehand. In this way, these experiments were mainly aimed at unraveling the oxidation rate and at quantifying the production of hydrogen-rich gases from the reactions of the metallic aluminum-rich by-products in a water-rich alkaline (liquid or vapor) environment. Reactions were carried out in a stainless-steel batch mini-reactor with metering and sampling valves, with the resulting gases analyzed by gas-chromatography (GC). The experimental setup was planned to avoid the following issues: (i) the corrosion of the reactor by the alkaline solution and (ii) the permeability of the system to hydrogen (i.e., possible leaks of H₂), related to the fast kinetics and short duration of the reactions (which may hinder a pile-up-effect) between the solid by-products and the liquid. The procedure was defined by a controlled interaction process between metals and liquid, using NaOH to increase reaction rates. The experimental runs performed in the mini-reactor proved to be effective for eliminating the reactive metallic aluminum, reaching a maximum hydrogen production of 96% of the total gases produced in the experiments. The relations between gas generation (up to 55 bar of H₂ in the experiments, which lasted for four days) and each specific parameter variation are discussed. All the obtained results can be transferred and applied to (i) the possible industrialization of the method for the chemical neutralization of these dangerous by-products, increasing sustainability and workplace safety, (ii) the use of the resulting hydrogen as a source of energy for the furnaces of the secondary aluminum industry itself, and (iii) new technological materials (e.g., “foamed geopolymers”), by using hydrogen as a foaming agent, coupled with aluminosilicate materials, during geopolymeric reactions.