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Foamed geopolymer materials are increasingly studied due to their inherent fire resistance. To date, these materials have primarily been produced by casting into moulds, with foaming occurring during mixing or within the moulds, shortly before setting. For practical applications, however, it is advantageous to apply these materials directly onto surfaces with complex geometries. Although several techniques for geopolymer spraying have been described in the literature, many exhibit limitations that restrict their practical implementation. This study presents a novel spraying technology developed on a dedicated process line, enabling in situ dosing of the foaming agent immediately before application. The system integrates infrared heating to ensure controlled curing of the geopolymer. This paper outlines the design of the process line and its core functionalities while presenting selected results of material tests conducted on the obtained geopolymer coatings. Tests performed on approximately 200 m2 of surface confirmed the functionality of the process. The thermal conductivity of the sprayed foams was about 0.07 W/m-K. The inclusion of a phase-change material (PCM) in the geopolymers further enhanced their ability to store and regulate thermal energy. The adhesion strength results, consistently exceeding 1 MPa across various substrates (steel, geopolymer, gypsum board), confirmed the practical suitability of the proposed solution. This was also demonstrated by the homogeneous foamed structure obtained.

Geopolymer concretes, synthesized from industrial by-products such as fly ash through alkaline activation, have attracted considerable attention due to their favorable thermal and microstructural properties. Incorporating phase change materials (PCMs) into geopolymer matrices can improve thermal properties, making them suitable for various sustainable construction applications. The thermal properties of geopolymer concrete depend on the composition and structure of the materials used. Adding PCMs to geopolymer concrete can significantly improve its thermal properties by increasing its heat storage capacity. PCMs absorb and release thermal energy during phase transformations, which can help regulate temperature fluctuations in building materials. This feature is particularly beneficial in regions with extreme temperature fluctuations, where maintaining a stable indoor climate is crucial. Integrating organic PCMs into geopolymer matrices has been shown to improve thermal insulation. Furthermore, the microstructural analysis of geopolymer concrete containing organic PCM indicates that incorporating these materials can lead to a more homogeneous and denser microstructure. Integrating organic PCMs instead of inorganic into geopolymer concrete is a promising route to improve thermal properties and microstructural stability. The combination of geopolymer technology with PCM not only contributes to the sustainable development of building materials but also addresses the challenges of temperature regulation in buildings.

In recent years, 3D concrete printing technology has been developing dynamically. Intensive research is still being carried out on the composition of the materials dedicated to innovative 3D printing solutions. Here, for the first time, concrete-geopolymer hybrids produced with 3D printing technology and dedicated environmentally friendly building construction are presented. The concrete-geopolymer hybrids consisting of 95% concrete and 5% geopolymer based on fly ash or metakaolin were compared to standard concrete. Moreover, 3D printed samples were compared with the samples of the same composition but prepared by the conventional method of casting into molds. The phase composition, water leachability, compressive, and flexural strength in the parallel and perpendicular directions to the printing direction, and fire resistance followed by compressive strength were evaluated. Concrete-geopolymer hybrids were shown to contain a lower content of hazardous compounds in leaches than concrete samples. The concentration of toxic metals did not exceed the limit values indicated in the Council Decision 2003/33/EC; therefore, the materials were classified as environmentally neutral. The different forms of Si/Al in fly ash and metakaolin resulted in the various potentials for geopolymerization processes, and finally influenced the densification of the hybrids and the potential for immobilization of toxic elements. Although the compressive strength of concrete was approximately 40% higher for cast samples than for 3D printed ones, for the hybrids, the trend was the opposite. The addition of fly ash to concrete resulted in a 20% higher compressive strength compared to an analogous hybrid containing the addition of metakaolin. The compressive strength was 7–10% higher provided the samples were tested in the parallel direction to the Z-axis of the printout. The sample compressive strength of 24–43 MPa decreased to 8–19 MPa after the fire resistance tests as a result of moisture evaporation, weight loss, thermal deformation, and crack development. Importantly, the residual compressive strength of the hybrid samples was 1.5- to 2- fold higher than the concrete samples. Therefore, it can be concluded that the addition of geopolymer to the concrete improved the fire resistance of the samples.

This study examines the relationship between the size of copper particles and the properties of epoxy resin. Epoxy resin is a type of thermosetting resin commonly used as a matrix in polymer matrix composite materials reinforced with glass or carbon fibers. As part of this study, three microscale and two nanoscale composite samples modified with copper oxide particles of varying sizes were produced. This study included mechanical property tests such as static tensile tests, static bending tests, and impact tests. The results of the strength tests were compared to modeling results. Additionally, an accelerated thermal aging process was conducted to determine the impact of external conditions on the behavior of the produced composites. This study concluded with an analysis of thermal conductivity. The test results revealed that the size of the copper particles significantly impacted the tested properties. The composites with copper oxide particles on the nanoscale demonstrated the best results. These composites have promising applications in the automotive and aviation industries due to their strength, resistance to external factors, and increased thermal conductivity, suggesting their potential for producing materials that effectively dissipate heat.

Nowadays, one very dynamic development of 3D printing technology is required in the construction industry. However, the full implementation of this technology requires the optimization of the entire process, starting from the design of printing ideas, and ending with the development and implementation of new materials. The article presents, for the first time, the development of hybrid materials based on a geopolymer or ordinary Portland cement matrix that can be used for various 3D concrete-printing methods. Raw materials used in the research were defined by particle size distribution, specific surface area, morphology by scanning electron microscopy, X-ray diffraction, thermal analysis, radioactivity tests, X-ray fluorescence, Fourier transform infrared spectroscopy and leaching. The geopolymers, concrete, and hybrid samples were described according to compressive strength, flexural strength, and abrasion resistance. The study also evaluates the influence of the liquid-to-solid ratio on the properties of geopolymers, based on fly ash (FA) and metakaolin (MK). Printing tests of the analyzed mixtures were also carried out and their suitability for various applications related to 3D printing technology was assessed. Geopolymers and hybrids based on a geopolymer matrix with the addition of 5% cement resulted in the final materials behaving similarly to a non-Newtonian fluid. Without additional treatments, this type of material can be successfully used to fill the molds. The hybrid materials based on cement with a 5% addition of geopolymer, based on both FA and MK, enabled precise detail printing.

Due to its structure and properties, diatomite from a deposit in Jawornik Ruski (Subcarpathian Voivodeship) can be used as a sorbent in rain gardens. The purpose of the current research is to analyze how enriching the substrate used in a rain garden with diatomite can affect the removal of biogenic pollutants. This study was carried out under laboratory conditions using retention columns, two experimental columns with different contents of diatomite, and a control column without the addition of diatomite. Analyses of the materials used included studies of the characteristics of the rain garden layers (water permeability and granulometric analysis) and characterization of the diatomite (SEM images, oxide and phase composition, leachability, and BET). The effects of diatomite on pollutant removal were studied for NH4+, PO43−, NO3−. The results showed approximately 3-fold higher reductions in the concentration of NH4+ and PO43− in the columns with the addition of diatomite than in the control one (reduction in the concentration of NH4+ by 93 and 94% and of PO43− by 94 and 98% with the addition of 20 and 30% diatomite contents, respectively). The study results confirmed the possibility of removing contaminants using diatomite, thus reducing their entry into the aquatic environment.

The article presents the results of research on foamed geopolymer materials as potentially dual-function building materials, combining thermal insulation properties with the ability to physically adsorb carbon dioxide. The materials were developed on the basis of fly ash, using hydrogen peroxide as a foaming agent. Two variants of the foaming agent quantity were used to assess how this quantity affects the type of porosity, thermal insulation, and CO adsorption capacity. The porous structure was characterised using mercury porosimetry and physical CO adsorption. A full analysis of their insulating and accumulating properties was also carried out. Measurements of the thermal conductivity coefficient (λ) showed that these materials have low thermal conductivity (in the range of 0.101 W/m·K), which confirms their suitability as ecological building insulators. At the same time, sorption tests performed using a physical sorption analyser confirmed the ability of selected composites to adsorb CO , with a noticeable influence of porosity parameters depending on the amount of blowing agent used on the efficiency of the process. An unexpected result of the research was the conclusion that a smaller amount of foaming agent may be more beneficial in terms of CO adsorption capacity, while maintaining similar insulation parameters. The results suggest that properly designed foamed geopolymers can serve a dual function – as insulation materials and passive CO adsorbents, thus supporting efforts towards sustainable development and decarbonisation of construction. The results obtained provide a basis for further in-depth analyses related to the possibility of using foamed geopolymers as carbon dioxide-absorbing materials.

The main objective of this article is to develop ceramic-based materials for additive layer manufacturing (3D printing technology) that are suitable for civil engineering applications. This article is focused on fly ash-based fiber-reinforced geopolymer composites. It is based on experimental research, especially research comparing mechanical properties, such as compressive and flexural strength for designed compositions. The comparison includes various composites (short fiber-reinforced geopolymers and plain samples), different times of curing (investigation after 7 and 28 days), and two technologies of manufacturing (casted and injected samples—simulations of the 3D printing process). The geopolymer matrix is based on class F fly ash. The reinforcements were green tow flax and carbon fibers. The achieved results show that the mechanical properties of the new composites made by injection methods (simulations of 3D technology) are comparable with those of the traditional casting process. This article also discusses the influence of fiber on the mechanical properties of the composites. It shows that the addition of short fibers could have a similar influence on both of the technologies.

Irreversible climate change, including atmosphere temperature extremes, is one of the most important issues of the present time. In this context, the construction industry requires solutions for increasing the energy efficiency of buildings through feedback between temperature adjustment inside buildings and better isolation of the external parts of buildings. Newly developed thermal insulation materials play an important role in this strategy. This paper presents the foamed geopolymer based on metakaolin that can be used as a modern facade material. In order to further improve its thermal insulation properties, the composition of geopolymer was modified with organic substances, i.e., perlite and cellulose fibers (30% and 50% of the volume). The thermal conductivity and insulation properties, density, mineral phases, absorbability, and compressive strength were improved for composite materials. It has been shown that the final properties of the foamed geopolymer can be controlled to a great extent by modifications, and the final properties determine its applicability.

The main objective of this study is to develop the advanced composites for civil engineering applications as material for the building industry, especially for an insulation purpose. The research processes include several steps. Firstly, the prototype elements, such as bricks and elevation elements were performed from eco-friendly composite -flax fiber reinforced geopolymer. The elements were designed to take into consideration for environment. Geopolymers are environmentally friendly, sustainable, and resource efficient, including energy demand. Next, the wall was built from these elements and exposed during the three months in a relevant environment. The main conclusion of the research is that the kind of fibers is important for the mechanical properties of the composite, including the fact that for those different fibers could be more beneficial for different raw materials, giving higher strength properties. The significant influence on the mechanical properties of the composites has the adhesion between fiber and material used as a matrix. The adhesion depends among others on the previous treatment of the fibers.