Sustainable Geopolymer Tuff Composites Utilizing Iron Powder Waste: Rheological and Mechanical Performance Evaluation

Mohamed Lyes Kamel Khouadjia, Sara Bensalem, Cherif Belebchouche (), Abderrachid Boumaza, Salim Hamlaoui and Slawomir Czarnecki ()
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Mohamed Lyes Kamel Khouadjia: Laboratory of Materials and Durability of Constructions (LMDC), Department of Civil Engineering, University of Constantine 1 Frères Mentouri, Constantine 25000, Algeria
Sara Bensalem: Laboratory of Materials and Durability of Constructions (LMDC), Department of Civil Engineering, University of Constantine 1 Frères Mentouri, Constantine 25000, Algeria
Cherif Belebchouche: Laboratory of Materials and Durability of Constructions (LMDC), Department of Civil Engineering, University of Constantine 1 Frères Mentouri, Constantine 25000, Algeria
Abderrachid Boumaza: Laboratory of Materials and Durability of Constructions (LMDC), Department of Civil Engineering, University of Constantine 1 Frères Mentouri, Constantine 25000, Algeria
Salim Hamlaoui: Laboratory of Materials and Durability of Constructions (LMDC), Department of Civil Engineering, University of Constantine 1 Frères Mentouri, Constantine 25000, Algeria
Slawomir Czarnecki: Department of Materials Engineering and Construction Processes, Wroclaw University of Science and Technology, Wybrzeze Wyspianskiego 27, 50-370 Wroclaw, Poland

Sustainability, 2025, vol. 17, issue 3, 1-17

Abstract: Geopolymers are a sustainable alternative to Portland cement, with the potential to significantly reduce the carbon footprint of conventional cement production. This study investigates the valorization of industrial waste iron powder (IP) as a fine filler in geopolymers synthesized from volcanic tuff (VTF). Composites were prepared with IP substitutions of 5%, 10%, and 20% by weight, using sodium hydroxide and sodium silicate as alkaline activators. Microstructural and phase analyses were conducted using scanning electron microscope coupled with energy dispersive X-ray spectroscopy (SEM-EDS), X-ray fluorescence (XRF), X-ray diffraction (XRD), and differential scanning calorimetry (DSC), while rheological properties, compressive strength, and flexural strength were assessed. The impact of curing temperatures (25 °C and 80 °C) on mechanical performance was evaluated. Results revealed that air content increased to 3.5% with 20% IP substitution, accompanied by a slight rise in flow time (0.8–2 s). Compressive and flexural strengths at 25 °C decreased by up to 22.48% and 28.39%, respectively. Elevated curing at 80 °C further reduced compressive and flexural strengths by an average of 45.30% and 64.68%, highlighting the adverse effects of higher temperatures. Although these formulations are not suitable for load-bearing applications, the findings suggest potential for non-structural uses, such as pavement base layers, aligning with sustainable construction principles by repurposing industrial waste and reducing reliance on energy-intensive cement production.

Keywords: eco-friendly geopolymer; carbon footprint; iron powder; waste; volcanic tuff; sustainable construction; properties characterization (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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