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The focus of this study is the fabrication of innovative and sustainable ceramic-based geopolymer with improved low temperatures performances. Kaolin was mixed with liquid sodium silicate (Na2SiO3) and 12M of sodium hydroxide (NaOH) solution using alkali activator ratio of 0.24 and solid-to-liquid ratio of 1:1 to synthesize kaolin geopolymer. The effect of the sintering profile on the microstructure, pore evolution and flexural strength were investigated. The heating exposure aided consolidation and created a fairly uniform microstructure, resulting in a smooth surface texture. In comparison to the unheated geopolymer, 3D pore distribution showed a significant increase in the range size of ~30 µm with the appearance of isolated and intergranular pores. The flexural strength at 1200 °C with a heating rate of 5 °C/min and was increased by 146.4% to 85.4 MPa, as compared to the heating rate of 2 °C/min. The sintering process has an impact on the final microstructure formation thus improving the characteristic of geopolymer-based nepheline ceramic. [ABSTRACT FROM AUTHOR]

Ceramics are highly valued for their exceptional thermal resistance and ability to withstand high temperatures. This study investigated the production of ceramic-like pressed geopolymer, focusing on the effects of aging period and sintering temperature. The results showed that the 7-day pressed geopolymer achieved the highest compressive (134.7 MPa) and flexural (34.9 MPa) strengths after sintering at 1000°C, with a density retention of 93.7 %, a mass loss of 7.9 %, and a thermal shrinkage of 1.4 %. Microstructural analysis at 1000°C showed a dense ceramic-like structure with nepheline formation. Phase analysis of the 7-day pressed geopolymer revealed a decrease in the amorphous phase as temperature increased, with nepheline formed at 800°C (26.0 %) and maximized at 1000°C (61.0 %). This work offers an optimal aging period and sintering temperature to maximize the mechanical strength and nepheline crystal formation, making them perfect for fire-resistant panels and precast construction products. • Pressed geopolymer was formed at various aging times and sintering temperatures. • The highest mechanical strength was achieved by the 7d pressed geopolymer at 1000°C. • The residual compressive strength at 1000°C ascends in 28d < 7d < 1d. • Gel matrix transformed into a ceramic-like structure with rising temperature. • The 7d pressed geopolymer has the most nepheline phase formation at 1000°C. [ABSTRACT FROM AUTHOR]

[Display omitted] • A study of fly ash based pressed and cast geopolymer was proposed. • Compressive strength of pressed geopolymer nearly twice that of cast geopolymer. • Flexural strength of pressed geopolymer was 5 times higher than cast geopolymer. • The highly compacted pressed geopolymer reduced the tendency of efflorescence. • The low alkali activator of pressing method lowered EE, ECO 2 and ECI of geopolymer. The high liquid content of cast geopolymer not only limits its strength development and durability but also leads to high energy consumption and carbon dioxide (CO 2) emissions. Thus, a study of the cast and pressed geopolymer was performed. The geopolymers were cured for 1, 7 and 28 d before testing and characterizations. With the incorporation of pressure compaction, higher bulk density (2158–2227 kg/m3) was recorded for pressed geopolymer in comparison to cast geopolymer (1842–1854 kg/m3). The dense matrix in pressed geopolymer improved the inter-particle contact, increasing the 28 d degree of reaction to 39.7%, higher than that of cast geopolymer (33.0%). This feature was proved by SEM micrographs wherein the pressed geopolymer was well-compacted and denser in microstructure, with less unreacted/partially reacted fly ash and pores. The compressive and flexural strengths of pressed geopolymer reached 114.2 and 29.9 MPa after 28 d, higher than that of cast geopolymer (60.0 and 6.2 MPa, respectively). The strength reduction of pressed geopolymer (31.7%) after the accelerated efflorescence test was lower than that of cast geopolymer (60.2%). The ecological analysis inferred that pressed geopolymer was ecologically superior to the casting method in terms of embodied energy (EE) and embodied carbon dioxide emission (ECO 2), in which 50% and 59% of reductions are acquired. Besides, the embodied carbon index (ECI) of pressed geopolymer was about 21% of cast geopolymer. [ABSTRACT FROM AUTHOR]

This paper compared the thermal stability between fly ash (FA) and fly ash-ladle furnace slag (FA-LS) geopolymers. FA-LS geopolymer was prepared by mixing FA and LS (FA:LS weight ratio of 80:20) with an alkali activator. Geopolymers were aged at room temperature for 28 days before being exposed to high temperatures (200 °C – 1000 °C). Unexposed FA and FA-LS geopolymers had a compressive strength of 38.9 MPa and 40.5 MPa, respectively. The FA and FA-LS geopolymers retained 61.6% and 91.3% compressive strength, respectively, when exposed to temperatures up to 1000 °C. FA-LS geopolymers experienced smaller variation in the density (2.6 – 5.5%) and pores (17.4 – 23.0%) compared to FA geopolymers (density and porosity of 2.9 – 25.2% and 19.0 – 30.0%, respectively). The formation of crystalline peaks, densification of matrix, pores and their connectivity, cracks and dimensional changes influenced the compressive strength of exposed geopolymers. FA-LS geopolymers could be potentially applied as heat-resistance material. [ABSTRACT FROM AUTHOR]