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The investigation of mould inserts in the injection moulding process using metal epoxy composite (MEC) with pure metal filler particles is gaining popularity among researchers. Therefore, to attain zero emissions, the idea of recycling metal waste from industries and workshops must be investigated (waste free) because metal recycling conserves natural resources while requiring less energy to manufacture new products than virgin raw materials would. The utilisation of metal scrap for rapid tooling (RT) in the injection moulding industry is a fascinating and potentially viable approach. On the other hand, epoxy that can endure high temperatures (>220 °C) is challenging to find and expensive. Meanwhile, industrial scrap from coal-fired power plants can be a precursor to creating geopolymer materials with desired physical and mechanical qualities for RT applications. One intriguing attribute of geopolymer is its ability to endure temperatures up to 1000 °C. Nonetheless, geopolymer has a higher compressive strength of 60–80 MPa (8700–11,600 psi) than epoxy (68.95 MPa) (10,000 psi). Aside from its low cost, geopolymer offers superior resilience to harsh environments and high compressive and flexural strength. This research aims to investigate the possibility of generating a new sustainable material by integrating several types of metals in green geopolymer metal composite (GGMC) mould inserts for RT in the injection moulding process. It is necessary to examine and investigate the optimal formulation of GGMC as mould inserts for RT in the injection moulding process. With less expensive and more ecologically friendly components, the GGMC is expected to be a superior choice as a mould insert for RT. This research substantially impacts environmental preservation, cost reduction, and maintaining and sustaining the metal waste management system. As a result of the lower cost of recycled metals, sectors such as mould-making and machining will profit the most. [ABSTRACT FROM AUTHOR]

Ordinary Portland cement (OPC) is a conventional material used to construct rigid pavement that emits large amounts of carbon dioxide (CO2) during its manufacturing process, which is bad for the environment. It is also claimed that OPC is susceptible to acid attack, which increases the maintenance cost of rigid pavement. Therefore, a fly ash based geopolymer is proposed as a material for rigid pavement application as it releases lesser amounts of CO2 during the synthesis process and has higher acid resistance compared to OPC. This current study optimizes the formulation to produce fly ash based geopolymer with the highest compressive strength. In addition, the durability of fly ash based geopolymer concrete and OPC concrete in an acidic environment is also determined and compared. The results show that the optimum value of sodium hydroxide concentration, the ratio of sodium silicate to sodium hydroxide, and the ratio of solid-to-liquid for fly ash based geopolymer are 10 M, 2.0, and 2.5, respectively, with a maximum compressive strength of 47 MPa. The results also highlight that the durability of fly ash based geopolymer is higher than that of OPC concrete, indicating that fly ash based geopolymer is a better material for rigid pavement applications, with a percentage of compressive strength loss of 7.38% to 21.94% for OPC concrete. This current study contributes to the field of knowledge by providing a reference for future development of fly ash based geopolymer for rigid pavement applications. [ABSTRACT FROM AUTHOR]

In this paper, the development of fire-resistant geopolymers for the passive fire protection of buildings is investigated. The fire-resistant geopolymeric materials were based on the alkali activation of a metallurgical slag produced in primary copper industry with a highly alkaline solution of potassium hydroxide. In order to decrease the density of the developed geopolymers, their foaming or the addition of lightweight aggregates was also studied. The physical, mechanical and thermal properties of the developed materials were determined and their performance upon exposure to fire was tested according to the ISO-834 standard time–temperature curve, which is considered as appropriate for testing fire protection systems employed in buildings. During the whole test of the materials performance against fire, the temperature at the interface between concrete and geopolymer was recorded below 180 °C, as required by the ISO test followed, proving effectiveness for the developed materials to be used as a thermal barrier in buildings and constructions. After testing, the geopolymers kept their structural integrity, without presenting any significant macroscopic damage. [ABSTRACT FROM AUTHOR]

The amount of sludge wastes produced from mining, domestic agriculture and industrial activities are about 60200 tons per year. The waste increase will have a significant impact on the energy conservation and also on the environment. Many attempts have been made to use sludge waste as construction materials such as brick; for example sewage sludge, water sludge, ceramic sludge and fly ash sludge and also advantages on the properties have been found but heavy metals leachibility will be the main concerned. Geopolymer has an ability to encapsulate heavy metals. Therefore, sludge waste is a potential alternative to convert into useful products as building materials that can alleviate the disposal problems. Therefore, in this study the potential of sludge waste to be utilize as construction materials has been studied. [ABSTRACT FROM AUTHOR]

In Malaysia there are six coal fired electric power station for the time being. These power stations usually can produce a high amount of electric power of more than 2400 MW. In peninsular Malaysia, there are four coal fired electric power station that produced at least 1400 MW of electric power. Coal fired electric power station is one of the cheapest electric production compared to the amount of power that can be produced. These power stations are still not enough to cater demand due tofuture development. Fly ash is a waste byproduct of electric power plants which use coal as their fuel source. Previously, a coal based power station disposed the waste amounts out of their equipment by burying it in landfills or returning it to strip mines. The growth in power plants that use coal as the source of fuel has produced hundreds of millions of tons of ash every year. With the advancement of technology and the economic crisis in Malaysia, the development of infrastructure in the use of new structural materials has been promoted but overall with unsatisfactory results in terms of cost savings. However, this problem can be solved by using waste industrial waste such as fly ash as a source to replace the existing building materials which is cost effective. The main aspect of waste management is to prevent the production of waste through minimizing the waste produced and also re-use of waste materials through recycling. The paper will be discussing the potential of managing waste of fly ash by utilizing it as construction materials. [ABSTRACT FROM AUTHOR]

This study intended to address the problem of damaged (collapsed, cracked and decreased soil strength) road pavement structure built on clay soil due to clay soil properties such as low shear strength, high soil compressibility, low soil permeability, low soil strength, and high soil plasticity. Previous research reported that ground granulated blast slag (GGBS) and fly ash can be used for clay soil stabilizations, but the results of past research indicate that the road pavement construction standards remained unfulfilled, especially in terms of clay's subgrade soil. Due to this reason, this study is carried out to further investigate soil stabilization using GGBS and fly ash-based geopolymer processes. This study investigates the effects of GGBS and ratios of fly ash (solid) to alkaline activator (liquid) of 1:1, 1.5:1, 2:1, 2.5:1, and 3:1, cured for 1 and 7 days. The molarity of sodium hydroxide (NaOH) and the ratio of sodium silicate (Na2SiO3) to sodium hydroxide (NaOH) was fixed at 10 molar and 2.0 weight ratio. The mechanical properties of the soil stabilization based geopolymer process were tested using an unconfined compression test, while the characterization of soil stabilization was investigated using the plastic limit test, liquid limit test, scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FTIR). The results showed that the highest strength obtained was 3.15 MPA with a GGBS to alkaline activator ratio of 1.5 and Na2SiO3 to NaOH ratio of 2.0 at 7 days curing time. These findings are useful in enhancing knowledge in the field of soil stabilization-based geopolymer, especially for applications in pavement construction. In addition, it can be used as a reference for academicians, civil engineers, and geotechnical engineers. [ABSTRACT FROM AUTHOR]

The demand for durable, resistant, and high-strength structural material has led to the use of fibers as reinforcing elements. This paper presents an investigation into the inclusion of chopped steel wool fibers (CSWFs) in cement to form a high-flexural strength cementitious composite matrix (CCM). CSWFs were used as the primary reinforcement in CCM at increments of 0.5 wt%, from 0.5–6 wt%, with ratios of cement to sand of 1:1.5 and water to cement of 0.45. The inclusion of CSWFs resulted in an excellent optimization of the physicomechanical properties of the CCM, such as its density (2.302 g/cm3), compressive strength (61.452 MPa), and maximum flexural strength (10.64 MPa), all of which exceeded the performances of other reinforcement elements reported in the literature. [ABSTRACT FROM AUTHOR]

In recent years, research and development of geopolymers has gained significant interest in the fields of repairs and restoration. This paper investigates the application of a geopolymer as a repair material by implementation of high-calcium fly ash (FA) as a main precursor, activated by a sodium hydroxide and sodium silicate solution. Three methods of concrete substrate surface preparation were cast and patched: as-cast against ordinary Portland cement concrete (OPCC), with drilled holes, wire-brushed, and left as-cast against the OPCC grade 30. This study indicated that FA-based geopolymer repair materials (GRMs) possessed very high bonding strength at early stages and that the behavior was not affected significantly by high surface treatment roughness. In addition, the investigations using scanning electron microscopy (SEM) and energy-dispersive X-ray (EDX) spectroscopy have revealed that the geopolymer repair material became chemically bonded to the OPC concrete substrate, due to the formation of a C–A–S–H gel. Fundamentally, the geopolymer network is composed of tetrahedral anions (SiO4)4− and (AlO4)5− sharing the oxygen, which requires positive ions such as Na+, K+, Li+, Ca2+, Na+, Ba2+, NH4+, and H3O+. The availability of calcium hydroxide (Ca(OH)2) at the surface of the OPCC substrate, which was rich in calcium ions (Ca2+), reacted with the geopolymer; this compensated the electron vacancies of the framework cavities at the bonding zone between the GRM and the OPCC substrate. [ABSTRACT FROM AUTHOR]