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

Author

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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
    Department of Civil Engineering, Faculty of Technology, Setif 1 University—Ferhat Abbas, Sétif 19000, 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)

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.

Suggested Citation

  • Mohamed Lyes Kamel Khouadjia & Sara Bensalem & Cherif Belebchouche & Abderrachid Boumaza & Salim Hamlaoui & Slawomir Czarnecki, 2025. "Sustainable Geopolymer Tuff Composites Utilizing Iron Powder Waste: Rheological and Mechanical Performance Evaluation," Sustainability, MDPI, vol. 17(3), pages 1-17, February.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:3:p:1240-:d:1583221
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    References listed on IDEAS

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    1. Mohammad Zahirul Khaiyum & Sudipa Sarker & Golam Kabir, 2023. "Evaluation of Carbon Emission Factors in the Cement Industry: An Emerging Economy Context," Sustainability, MDPI, vol. 15(21), pages 1-15, October.
    2. Rana Muhammad Waqas & Shahid Zaman & Mohammed K. Alkharisi & Faheem Butt & Eyad Alsuhaibani, 2024. "Influence of Bentonite and Polypropylene Fibers on Geopolymer Concrete," Sustainability, MDPI, vol. 16(2), pages 1-19, January.
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