The use of recycled powder as a binder in geopolymer concrete (GPC) represents a promising approach to reducing construction waste and promoting the production of sustainable materials. This study examines the impact of recycled concrete powder (RCP), clay brick powder (CBP), and volcanic pumice powder (VPP) on the mechanical, durability, and thermal properties of GPC with fly ash and slag under water curing. Key mechanical properties, including compressive strength (CS), splitting tensile strength, and flexural strength, were evaluated, while durability was assessed through water absorption, water penetration, and resistance to sulfate and acid attacks. The thermal performance was tested by exposing the samples to elevated temperatures of 200 °C, 400 °C, and 600 °C. Results demonstrated that incorporating 25% RCP enhanced CS by 14.88% at 28 days compared to the control mixture, although higher replacement levels (50% and 75%) led to reduced CS due to increased porosity. Similarly, CBP at 25% substitution resulted in a 21.12% increase in CS, with declines observed at higher replacement levels. Conversely, VPP at 25% substitution decreased CS by 8.68% at 28 days, with further significant reductions at higher levels due to its high porosity. Sulfate resistance testing in a 5% MgSO₄ solution showed minimal mass loss for CBP mixtures (0.3–1.2%) and moderate CS reductions (5.7–29.6%). RCP mixtures exhibited low mass loss (0.3–1.7%) and CS reductions (8.7–15.8%), while VPP mixtures experienced the highest mass losses (1.36–3.4%) and CS reductions (20.5–31.3%). SEM analysis revealed that RCP and CBP mixtures exhibited denser microstructures, which contributed to their enhanced durability and thermal stability. Generally, optimizing the replacement levels of RCP, CBP, and VPP improves the durability, pore structure, and mechanical performance of GPC. Among the materials, CBP demonstrated superior resistance in acidic environments, while RCP excelled in thermal stability, demonstrating their potential for producing sustainable and durable geopolymer concrete.

The incorporation of construction and demolition (C&D) waste in concrete production has gained great importance toward sustainability, especially in geopolymer concrete. In this study, ground granulated blast-furnace slag (GGBFS) and fine aggregate of normal geopolymer concrete were partially replaced by clay brick powder (CBP) and fine clay brick (FCB) derived from C&D waste, respectively, aiming to produce high-strength geopolymer concrete (HSGC). Fly ash (FA) was also used as a partial replacement for GGBFS in normal geopolymer concrete. Twenty HSGC mixtures were designed using the response surface methodology with three variables, including CBP (0–25%), FA (0–25%), and FCB (0–50%). The performance of the proposed HSGC mixtures was assessed by measuring several mechanical and durability properties. In addition, a variety of physicochemical methods, including X-ray fluorescence spectroscopy, X-ray diffraction, and scanning electron microscopy, were used to examine the mineralogical and microstructural characteristics of the control and the developed mixtures. The findings revealed that the compressive, splitting tensile, and flexural strengths of the HSGC made with C&D waste ranged from 38.0 to 70.3 MPa, 4.1 to 8.2 MPa, and 5.2 to 10.0 MPa, respectively. The results also indicated that the incorporation of FA is an essential parameter to eliminate the negative impacts of C&D waste addition on concrete workability. The optimal proportions for the HSGC were 5% for CBP, 5% for FA, and 40% for FCB, which were determined to generate the optimized HSGC with the highest mechanical performance, according to the verified models and optimization findings. The physicochemical analyses showed that the thick amorphous geopolymeric gel predominated the nonporous structure of the optimized HSGC, which had good mechanical characteristics. Furthermore, the anti-carbonation performance and freezing resistance of the optimal HSGC increased by 17.7% and 14.6%, respectively, while the apparent porosity decreased by 8.4%.

The main obstacle of using geopolymer as a construction repair material is its slow strength development rate, which is the most significant attribute of an early-age opening for traffic and striking-off formwork. Geopolymer technology has recently attracted huge interest as an alternative to traditional cementitious materials with low environmental impact. Thus, this study investigates the feasibility of developing an ultra-high performance geopolymer concrete (UHPGC) with the aim of achieving high early-age strength. For this purpose, UHPGC mixtures activated with different potassium hydroxide molarities and aluminosilicate material types were developed and examined being cured with different curing temperatures. The early strength and durability of the UHPGC after 8 and 24 h were investigated. Experimental results revealed that the optimal mix design of UHPGC corresponds to a KOH molarity of 16 M and a 30% silica fume content. Furthermore, former mixture cured at 100 °C gave superior 8 and 24 h early strength values of 79 and 134 MPa, respectively. Moreover, a superior interaction of slag, silica fume, and activator solution at early age for UHPGC is revealed by the microstructural characteristics examined by a field emission scanning electron microscope (FESEM) with energy dispersive X-ray spectroscopy (EDS), Fourier transform infrared spectroscopy analysis, and thermogravimetric (TGA) techniques. It was also found that the compressive strength results and the results of the microstructure analysis are well coincided. The experimental results obtained in this study emphasize the feasibility of using developed UHPGC as an eco-friendly quick repair materials The development of one-part UHPGC as a quick, cost-effective, and high-strength product for all construction repair maintenance will lead to huge improvements in the structural capacity and durability of structural components.

Engineered geopolymer composite (EGC) is a high-performance material with enhanced mechanical and durability capabilities. Ground granulated blast furnace slag (GGBFS) and silica fume (SF) are common binder materials in producing EGC. However, due to the scarcity and high cost of these materials in some countries, sustainable alternatives are needed. This research focused on producing eco-friendly EGC made of cheaper and more common pozzolanic waste materials that are rich in aluminum and silicon. Rice husk ash (RHA), granite waste powder (GWP), and volcanic pumice powder (VPP) were used as partial substitutions (10–50%) of GGBFS in EGC. The effects of these wastes on workability, unit weight, compressive strength, tensile strength, flexural strength, water absorption, and porosity of EGC were examined. The residual compressive strength of the proposed EGC mixtures at high elevated temperatures (200, 400, and 600 °C) was also evaluated. Additionally, scanning electron microscope (SEM) was employed to analyze the EGC microstructure characteristics. The experimental results demonstrated that replacing GGBFS with RHA and GWP at high replacement ratios decreased EGC workability by up to 23.1% and 30.8%, respectively, while 50% VPP improved EGC workability by up to 38.5%. EGC mixtures made with 30% RHA, 20% GWP, or 10% VPP showed the optimal results in which they exhibited the highest compressive, tensile, and flexural strengths, as well as the highest residual compressive strength when exposed to high elevated temperatures. The water absorption and porosity increased by up to 106.1% and 75.1%, respectively, when using RHA; increased by up to 23.2% and 18.6%, respectively, when using GWP; and decreased by up to 24.7% and 22.6%, respectively, when using VPP in EGC.