Geopolymers are considered to alternatives to Portland cement, providing an opportunity to exploit aluminosilicate wastes or co-products with promising performances in the construction sector. This research is aimed at investigating the strength of fly-ash-geopolymers of different ages. The effect of granulated blast furnace slag (GGBFS) as a partial replacement of fly ash (FA) on the tensile (f_t) and compressive strength (f_c), as well as the modulus of elasticity, is investigated. The main advantage of the developed geopolymer mixes containing GGBFS is their ability to set and harden at room temperature with no need for heating to obtain binding properties, reducing the energy consumption of their production processes. This procedure presents a huge advantage over binders requiring heat curing, constituting a significant energy savings and reduction of CO₂ emissions. It is found that the development of strength strongly depends on the ratio of fly-ash to granulated blast furnace slag. With the highest amount of GGBFS, the compressive strength of geopolymers made of fly-ash reached 63 MPa after 28 days of curing at ambient temperature. The evolution of compressive strength with time is correlated with the development of ultrasound pulse velocity methods, which are used to evaluate maturity. The modulus of elasticity changes with strength and the relationship obtained for the geopolymer is presented on the basis of typical models used for cement-based materials. The tensile to compressive strength ratios of the tested geopolymers are identified as higher than for cementitious binders, and the f_t(f_c) relationship is juxtaposed with dependencies known for cement binders, showing that the square root function gives the best fit to the results.

The inorganic structure formed at the stage of setting of the geopolymer binder ensures high durability of the material under high-temperature conditions. However, changes in the microstructure of the material are observed. The purpose of the study was to analyze changes in the structure of geopolymer mortar after exposure to high temperatures T = 200, 400, 600, 800, and 1000 °C. Mortars with a binder based solely on fly ash (FA) and mixed in the 1:1 ratio with a binder containing fly ash and ground granulated blast-furnace slag (GGBFS) were tested. The descriptions of their microstructures were prepared based on digital microscope observations, scanning electron microscope (SEM) observations, EDS (energy dispersive spectroscopy) analysis, and mercury intrusion porosimetry (MIP) porosity test results. Changes in the material due to high temperature were observed. The differences in the microstructure of the samples are also visible in the materials that were not exposed to temperature, which was influenced by the composition of the materials. Porosity increases with increasing annealing temperature. The distribution of individual pores also changes. In both materials, the proportion of pores larger than 1000 nm increases with the temperature increase. Moreover, the number of cracks and their width also increases, reaching 20 µm in the case of GGBFS. Furthermore, the color of geopolymers has changed. The obtained results extend the current state of knowledge in the field of changes in the microstructure of geopolymers subjected to high temperature.

Three-dimensional concrete printing (3DCP) is an emerging additive manufacturing technology with increasing application potential in the construction industry, offering advantages such as reduced labor requirements, shortened construction time, and material efficiency. However, structural integrity remains a challenge, particularly due to weak interlayer bonding resulting from the layered manufacturing process. This study investigates the mechanical performance and anisotropy of 3D-printed mineral-based composites with respect to the time interval between successive layers. Specimens were printed with varying interlayer intervals (0, 25, and 50 min) and tested in different loading directions. Flexural, compressive, and tensile strengths (direct and splitting methods) were measured both parallel and perpendicular to the layer orientation. Results showed a clear degradation in mechanical properties with increasing interlayer time, particularly in the direction perpendicular to the layers. Flexural strength decreased by over 25% and direct tensile strength by up to 40% with a 25 min interval. Compressive strength also declined, though less dramatically. Compared to cast specimens, printed elements showed 3–4 times lower compressive strength, highlighting the significant impact of interlayer cohesion. This study confirms that both the time between layers and the loading direction strongly influence mechanical behavior, underlining the anisotropic nature of 3DCP elements and the need for process optimization to ensure structural reliability.

Two geopolymer foams were prepared from a thermally activated coal gangue containing kaolinite. As the foaming agent, aluminium powder and 36% hydrogen peroxide were used to obtain two levels of porosity. The materials’ high temperature performances were investigated: tensile and compressive strength evolution with temperature. This study shows that the mechanical performances of developed geopolymer foams are similar to foam concrete of the same apparent density. The geopolymer foams from coal gangue present stable mechanical performances up to 600 °C. When the glass transition temperature is achieved, sintering occurs and mechanical performance increases. SEM observations confirm the glass transition and densification of the matrix at temperatures above 800 °C. Moreover, the XRD measurements revealed a high amount of mullite that forms at 1000 °C that explained the observed strength increase. The synthesis of good-quality geopolymer foams from coal gangue and its application as a thermal barrier is feasible. The constant level of porosity and its stable character in the range of temperatures 20–1000 °C ensures stable thermal insulation parameters with increasing temperature, which is extremely important for fire protection.

Geopolymers are less energy-demanding alternatives to Portland cement binders. The subject of geopolymer rheology has not yet been fully explored, and the available literature is limited to a narrow range of material compositions. This paper presents the rheological and mechanical response of fly-ash based geopolymer mortars. Investigations were made of the effect of different levels of ground granulated blast furnace slag (GGBFS) addition levels on the rheological properties of fresh geopolymers as well as their mechanical performances at 2, 14 and 28 days. The aim of the study was to obtain flow curves and to establish the correlation between shear stress and shear rate. The results have shown that geopolymer mortar is a pseudoplastic liquid presenting shear thinning behavior, moreover, with the increase of GGBFS content, higher material strengths were obtained and the total porosity was reduced.