In recent years, the mining industry of slate stone in Spain, from Castille and Leon, has grown significantly due to construction and building sector demands. The continuous accumulation of cutting sludges in ponds from mining and processing operations brings associated environmental problems if the cutting sludges are not properly treated. A potential environmental mitigation measure is the valorization of cutting sludges for the development of new binder materials through geopolymerization. Therefore, this research focused its attention on studying the feasibility of slate stone cutting sludges as a source of aluminosilicates for geopolymer conformation. For this experiment, the mining raw material was analyzed through a typical characterization test campaign in order to validate its feasibility as a source of aluminosilicates for geopolymerization. Subsequently, geopolymers were prepared with slate stone cutting sludges and a 12 M concentration using different Na₂SiO₃/NaOH ratios (5, 2.5, 1.6, 1.25, and 1). Geopolymer samples were tested, and their physical and mechanical characteristics were evaluated. The test results show that an alkali activator with a 2.5 ratio led to better mechanical and physical properties, with a 7-day compressive strength value of 27.23 MPa. Therefore, this research aims to demonstrate that slate stone cutting sludge could constitute a sustainable binder material for construction purposes.

The reuse of by-products as alternative raw materials to traditional construction materials is required in order to ensure sustainable development in the construction sector and is a significant and important focus in the fields of materials science. This study developed geopolymers using by-products from mining, ceramics, and olive industries, including slate stone cutting sludge (SSCS) and chamotte (CH) as aluminosilicate sources, and olive biomass bottom ash (OSBA) as an alkaline activator with sodium silicate. A key novelty of the research lies in the use of SSCS, an underexplored by-product in geopolymerization studies, as a viable aluminosilicate source. The geopolymers were prepared with varying weight ratios of SSCS, CH, and OSBA/Na₂SiO₃ (1.7, 1.9, 2.2, and 2.4). Physical and mechanical tests determined the optimal formulation, while FTIR and SEM analyses revealed the material’s chemical and structural evolution. The FTIR analysis detected the quartz and carbonate phases, indicating incomplete quartz dissolution and carbonate formation during calcination. The SEM analysis revealed a dense microstructure with reduced porosity and enhanced geopolymerization in samples with higher OSBA content. The optimal geopolymer (60% OSBA, 30% CH, OSBA/Na₂SiO₃ ratio of 2.2) achieved a compressive strength of 33.1 MPa after 28 days. These findings demonstrate the feasibility of producing geopolymers using SSCS, CH, and OSBA, promoting the reuse of industrial by-products as sustainable alternatives to conventional binders.

The sustainable development of building materials is based on reusing by-products to reduce environmental impact and promote alternatives to traditional materials. In this study, geopolymers were developed from by-products of the mining, ceramic, and thermal industries: slate stone cutting sludge (SSCS) and chamotte (CH) as aluminosilicate sources, and olive stone bottom ash (OSBA) as an alkaline activator, combined with sodium silicate (Na₂SiO₃). Eight geopolymer families were prepared with constant amounts of SSCS and CH and varying proportions of OSBA/Na₂SiO₃ (0.88–1.31). The evaluation phase included physical, chemical, mechanical, and microstructural tests. The results showed that the optimum geopolymer formulation (GP E) contained 25% SSCS, 15% CH, and 19% OSBA with a Na₂SiO₃/OSBA ratio of 1.0, achieving a compressive strength of 24.12 MPa after 28 days of curing. GP E also showed the lowest porosity (19.54%), minimal water absorption (6.86%), and favorable thermal conductivity (0.688 W/mK). Fourier transform infrared spectroscopy (FTIR) and scanning electron microscopy (SEM) confirmed the formation of dense and homogeneous matrices. These results demonstrate the feasibility of manufacturing geopolymers using SSCS, CH, and OSBA as substitutes for traditional binders, promoting sustainable practices, reusing industrial by-products, and reducing carbon emissions in construction.

The expansion of the construction sector has contributed to the depletion of raw materials and an increased demand for resources; therefore, sustainable approaches are required to satisfy the construction demand. The present study explores the development of geopolymers by utilizing industrial by-products from mining, ceramics, olive oil production, and steel manufacturing. Specifically, slate stone cutting sludge (SSCS) and chamotte (CH) are used as aluminosilicate precursors, with olive biomass bottom ash (OSBA) acting as an alkaline activator, along with sodium silicate, and steel granulated slag (SGS) incorporated as an aggregate. Novel geopolymers were prepared with consistent proportions of SSCS and OSBA while varying the CH content from 10 to 2 wt.%. The SGS proportion was adjusted from 35 to 50 wt.%, and different Na₂SiO₃/OSBA ratios (0.35, 0.31, 0.19, and 0.08) were examined. To identify the optimal mix, a series of physical and mechanical tests was conducted, complemented by FTIR and SEM analysis to evaluate the chemical and microstructural changes. The best-performing formulation achieved a compressive strength of 42.8 MPa after 28 days of curing. FTIR analysis identified quartz and carbonate phases, suggesting that quartz did not fully dissolve and that carbonates formed during the heating process. SEM examination of the optimal mixture indicated that the incorporation of SGS (up to 45 wt.%) facilitated the creation of a compact, low-porosity structure. EDX results revealed the presence of Ca-, Na-, Si-, Al-, and K-enriched phases, supporting the formation of (N, C)-A-S-H gel networks. These results demonstrate the potential of utilizing SSCS, CH, OSBA, and SGS to create geopolymer concretes, showcasing the viability of using industrial by-products as eco-friendly substitutes for traditional construction materials.

The forming methodology influences the physicochemical, mechanical, and microstructural properties. In this study, which aims to develop a geopolymeric material for potential insulation applications in buildings such as vertical walls, geopolymers were developed using industrial wastes from different industries: slate stone cutting sludge (SSCS) and chamotte (CH) were used as precursors, and olive stone bottom ash (OSBA) and sodium silicate (Na₂SiO₃) were used as alkaline activators. Two forming methods were evaluated: uniaxial pressing and casting of the material, varying the forming method and the liquid/solid ratio. The results showed that the pressed geopolymers achieved higher bulk densities (up to 2.13 g/cm³) and significantly higher compressive strength (28.04 MPa at 28 days), attributable to a higher compactness and degree of geopolymer reaction. In contrast, the casting geopolymers exhibited surface efflorescence, related to slower curing and higher porosity, which reduced their compressive strength (17.88 MPa). In addition, the pressed geopolymers showed better thermal stability and fire performance. These results demonstrate that the variation of the forming method has a direct influence on the material properties of geopolymers, and that the pressing process allows for a reduction of the alkaline activator content, thus reducing its environmental footprint.

This study evaluates the industrial-scale feasibility of injection moulding of a recycled polypropylene composite reinforced with recycled fibers derived from an industrial waste stream. Although previous laboratory-scale research has demonstrated the potential of natural fiber-reinforced thermoplastics, their large-scale industrial implementation remains limited due to uncertainties related to processability, reproducibility, and manufacturing robustness. In this work, the composite material is validated through injection moulding trials carried out in four independent industrial companies located in Andalusia (Spain) and three industrial case studies across different industrial sectors in Slovenia, operating under real production conditions. The extrusion process was characterized in terms of process stability, confirming continuous operation with automated dosing and stable material flow without interruptions under industrial conditions. Injection processing parameters, cycle stability, part quality, and defect formations are also considered important when assessing the manufacturing feasibility. The multi-site validation approach enables the evaluation of reproducibility across different injection moulding systems and mould geometries, providing critical insights into the scalability and technological readiness level of recycled natural fiber-reinforced polypropylene composites. Although direct energy consumption measurements were not systematically recorded, the observed processing stability and cycle repeatability indicate a consistent and energy-efficient operation under industrial processing conditions. The results contribute to bridging the gap between laboratory-scale material development and real industrial implementation.