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Globally, several million tons of various wastes are produced each year, and these quantities are projected to rise. Environmental issues arise from the landfilling or burning of many of these wastes. These wastes can gradually be used as replacement construction materials to reduce their harmful impacts on the environment. In this context, geopolymer foam concrete (GFC) could be used to incorporate these wastes in high volumes owing to its low strength requirement. GFC is a material developed by combing of foam concrete with geopolymer technologies. It helps reduce the consumption of natural resources, carbon dioxide, and energy used in buildings. GFCs have also emerged as one of the most intriguing composites in recent years thanks to their extraordinary benefits, low cost, and eco-friendly synthesis techniques. Recent developments in this area have led to the production of GFC, which combines performance advantages and operational energy savings with cradle-to-gate emissions reductions acquired using a geopolymer binder. This review discusses the sustainability of GFC with different wastes and major parameters affecting its stability, performance, and microstructure to provide a better understanding of the characteristics of GFC and its large-scale advantages. Limitations, challenges, and potential GFC futures for the various uses are outlined and extensively addressed. This review also presents the extraordinary potential of geopolymer foams in high-value applications as a PC-based foam alternative, which could encourage their broad technological utilization. Graphical abstracts

To address the demands of the low-carbon era, this study proposed a solution by using eggshell powder (ESP), fly ash, and ground granulated blast furnace slag together with alkaline solution in the preparation of lightweight geopolymer foam concrete (LWGFC). The aim of this study is to investigate the influence of replacing precursor materials with 5–20% ESP on the expansion behavior, physical, mechanical characteristics, and thermal conductivity of LWGFC. Additionally, the study examines the effect of varying the silicate modulus (SiO2/Na2O ratios of 1.0, 1.25, and 1.5) on the properties of LWGFC. Incorporating ESP from 5% to 20% with a constant SiO2/Na2O ratio reduced the initial setting time, while a high SiO2/Na2O ratio controlled the setting time and expansion volume. The high SiO2/Na2O ratio decreased the porosity and enhanced the compressive strength of the LWGFC but increased the thermal conductivity. The inclusion of more than 10% ESP content negatively affected compressive strength; however, a high SiO2/Na2O ratio can mitigate this detrimental effect. The thermal conductivity of optimal-content ESP mixtures with a SiO2/Na2O ratio of 1.0 was about 0.84 W/m·K, which is 2.1% lower than mixtures with a ratio of 1.25 and 18.6% lower than those with a ratio of 1.5. High-content ESP mixtures had a density of 1707 kg/m3, 0.97 W/m·K, and a compressive strength of 18.9 MPa at a low SiO2/Na2O ratio. Finally, the inclusion of ESP in the LWGFC, along with the use of an appropriate silicate modulus, resulted in improved strength development while decreasing porosity.

The development of sustainable, environmentally friendly insulation materials with a reduced carbon footprint is attracting increased interest. One alternative to conventional insulation materials are foamed geopolymers. Similar to foamed concrete, the mechanical properties of geopolymer foams can also be improved by using fibers for reinforcement. This paper presents an overview of the latest research findings in the field of fiber-reinforced geopolymer foam concrete with special focus on natural fibers reinforcement. Furthermore, some basic and background information of natural fibers and geopolymer foams are reported. In most of the research, foams are produced either through chemical foaming with hydrogen peroxide or aluminum powder, or through mechanical foaming which includes a foaming agent. However, previous reviews have not sufficiently addresses the fabrication of geopolymer foams by syntactic foams. Finally, recent efforts to reduce the fiber degradation in geopolymer concrete are discussed along with challenges for natural fiber reinforced-geopolymer foam concrete.

This study aims to investigate the geopolymerization reaction of geopolymer foams produced with three different foaming agents: aluminum powder, zinc powder, and hydrogen peroxide. The geopolymerization reaction of geopolymer foam was monitored using the [sup.27]Al and [sup.29]Si magic angle spinning (MAS) nuclear magnetic resonance (NMR) spectroscopy technique. [sup.27]Al MAS-NMR was used to monitor the reaction at an early stage, while [sup.29]Si and [sup.27]Al MAS-NMR analyses were employed at specific time intervals of 3, 6, 10, 15, and 28 days to examine the changes that occurred in the formed gel over time. We discussed in detail how the type of foaming agent used and the duration of the reaction both influence the quantity of gel formed and the amount of remnant fly ash. Our findings indicate that the type of foaming agent used affects the formation and structure of the gel, with aluminum powder leading to the highest gel formation. Additionally, the duration of the reaction plays a significant role in determining the quantity of remnant fly ash, with longer reaction times resulting in decreased fly ash content. This study sheds light on the relevance of understanding the role of foaming agents in the geopolymerization reactions of geopolymer foams and the influence of reaction time on the formed gel properties.

In this paper, four near-net shaped foams were produced via direct foaming, starting from a benchmark metakaolin-based geopolymer formulation. Hydrogen peroxide and metallic silicon were used in different amounts as blowing agents to change the porosity from meso- to ultra-macro-porosity. Foams were characterized by bulk densities ranging from 0.34 to 0.66 g cm−3, total porosity from 70% to 84%, accessible porosity from 41% to 52% and specific surface area from 47 to 94 m2 g−1. Gas permeability tests were performed, showing a correlation between the pore features and the processing methods applied. The permeability coefficients k1 (Darcian) and k2 (non-Darcian), calculated applying Forchheimer’s equation, were higher by a few orders of magnitude for the foams made using H2O2 than those made with metallic silicon, highlighting the differing flow resistance according to the interconnected porosity. The gas permeability data indicated that the different geopolymer foams, obtained via direct foaming, performed similarly to other porous materials such as granular beds, fibrous filters and gel-cast foams, indicating the possibility of their use in a broad spectrum of applications.

This paper presents temperature-dependent properties and fire resistance of geopolymer foams made of ground basalt fibers, aluminum foaming agents, and potassium-activated metakaolin-based geopolymers. Temperature-dependent properties of basalt-reinforced geopolymer foams (BGFs) were investigated by a series of measurements, including apparent density, water absorption, mass loss, drying shrinkage, compressive and flexural strengths, XRD, and SEM. Results showed that the apparent density and drying shrinkage of the BGFs increase with increasing the treated temperature from 400 to 1200 °C. Below 600 °C the mass loss is enhanced while the water absorption is reduced and they both vary slightly between 600 and 1000 °C. Above 1000 °C the mass loss is decreased rapidly, whereas the water absorption is increased. The compressive and flexural strengths of the BGFs with high fiber content are improved significantly at temperatures over 600 °C and achieved the maximum at 1200 °C. The BGF with high fiber loading at 1200 °C exhibited a substantial increase in compressive strength by 108% and flexural strength by 116% compared to that at room temperature. The enhancement in the BGF strengths at high temperatures is attributed to the development of crystalline phases and structural densification. Therefore, the BGFs with high fiber loading have extraordinary mechanical stability at high temperatures. The fire resistance of wood and steel plates has been considerably improved after coating a BGF layer on their surface. The coated BGF remained its structural integrity without any considerable macroscopic damage after fire resistance test. The longest fire-resistant times for the wood and steel plates were 99 and 134 min, respectively. In general, the BGFs with excellent fire resistance have great potential for fire protection applications.

The article deals with the investigation of geopolymer foams (GFs) synthesized using by-products coming from the (i) screening-, (iv) pyrolysis-, (iii) dust abatement- and (iv) fusion-processes of the secondary aluminum industry. Based on principles of the circular economy to produce new technological materials, the experimental study involves industrial by-products management through the recovery, chemical neutralization, and incorporation of these relatively hazardous waste into the GFs. The geopolymeric matrix, consisting of metakaolin (MK) and silica sand (SA) with a 1:1 wt.% ratio, and chopped carbon fibers (CFs, 1 wt.% MK), was doped with the addition of different aluminum-rich industrial by-products with a percentage from 1 to 10 wt.% MK. The gas (mainly hydrogen) produced during the chemical neutralization of the by-products represents the foaming agents trapped in the geopolymeric structure. Several experimental tests were carried out to characterize the mechanical (flexural, compressive, and Charpy impact strengths) and thermal properties (thermal conductivity, and diffusivity, and specific heat) of the GFs. Results identify GFs with good mechanical and thermal insulation properties, encouraging future researchers to find the best combination (for types and proportions) of the different by-products of the secondary aluminum industry to produce lightweight geopolymer foams. The reuse of these industrial by-products, which according to European Regulations cannot be disposed of in the landfill, also brings together environmental sustainability and safe management of hazardous material in workplaces addressed to the development of new materials.

We have calculated that with the world population projected to increase from 7.5 billion in 2017 to 9.8 in 2050, the next generation (within 33 years) will produce 12,000–13,000 Mt of plastic, and that the yearly consumption will reach 37–40 kilos of plastic per person worldwide. One of the branches of the plastics industry is the production of plastics for agriculture e.g., seed trays and pots. In this paper, novel metakaolin-based geopolymer composites reinforced with cellulosic fibres are presented as an alternative to plastic pots. Materials can be dedicated to agricultural applications, provided they have neutral properties, however, geopolymer paste and its final products have high pH. Therefore, a two-step protocol of neutralisation of the geopolymer foam pots was optimised and implemented. The strength of the geopolymer samples was lower when foams were neutralised. The reinforcement of geopolymers with cellulose clearly prevented the reduction of mechanical properties after neutralisation, which was correlated with the lower volume of pores in the foam and with the cellulose chemical properties. Both, neutralisation and reinforcement with cellulose can also eliminate an efflorescence. Significantly increased plant growth was found in geopolymer pots in comparison to plastic pots. The cellulose in geopolymers resulted in better adsorption and slower desorption of minerals during fertilisation. This effect could also be associated with a lower number of large pores in the presence of cellulose fibres in pots, and thus more stable pore filling and better protection of internal surface interactions.

Geopolymers are synthesized using anthropogenic raw materials and waste from the energy industry. Their preparation necessitates an alkaline activator, which facilitates the dissolution of raw materials and their subsequent binding. At present, geopolymers are considered a promising material with the potential to replace conventional cement-based products. This research investigates foamed geopolymer materials based on fly ash, natural fibers, and phase-change materials. The study utilized three distinct types of fibers and two phase-change materials manufactured by Rubitherm Technologies GmbH of Germany. This paper presents the results of the thermal conductivity coefficient and specific heat tests on the finished foams. Additionally, compressive strength tests were conducted on the samples after 28 days. Natural fibers decreased the insulation parameter by 12%, while PCM enhanced it by up to 6%. The addition of fibers increased the compressive strength by nearly 30%, whereas PCM reduced this by as little as 14%. Natural fibers and phase-change materials had an increased heat capacity by up to 35%. The results demonstrated the material’s potential in various industrial sectors, with the primary areas of application being building materials and insulations. The findings illustrate the significant potential of these composites as energetically and environmentally sustainable materials.

The development of sustainable construction materials with improved mechanical performance and thermal insulation and is crucial to addressing growing environmental and energy efficiency concerns. This study aimed to design and optimize foamed geopolymer composites incorporating recycled concrete sand (RCS), glass powder (GP), and date palm fibers (DPF) to improve compressive strength and thermal insulation. A comparative analysis of two modeling strategies, Central Composite Design (CCD) and Artificial Neural Network (ANN), was conducted to predict and optimize the effects of the three constituents. Experimental data were used to train and validate both models. The ANN model outperformed CCD in terms of predictive accuracy, particularly for thermal conductivity, as indicated by higher R² values and a greater overall desirability index (0.86 vs. 0.77). The ANN-optimized formulation (35.4% RCS, 4.96% GP, 0.23% DPF) achieved a compressive strength of 4.41 MPa and thermal conductivity of 0.141 W/mK. While ANN offers improved predictive capability, its limited interpretability remains a challenge. This research highlights the potential of integrating construction and agricultural waste into geopolymer matrices to produce eco-efficient building materials.