Geopolymer Ceramic Application: A Review on Mix Design, Properties and Reinforcement Enhancement

Abstract

Geopolymers have been intensively explored over the past several decades and considered as green materials and may be synthesised from natural sources and wastes. Global attention has been generated by the use of kaolin and calcined kaolin in the production of ceramics, green cement, and concrete for the construction industry and composite materials. The previous findings on ceramic geopolymer mix design and factors affecting their suitability as green ceramics are reviewed. It has been found that kaolin offers significant benefit for ceramic geopolymer applications, including excellent chemical resistance, good mechanical properties, and good thermal properties that allow it to sinter at a low temperature, 200 °C. The review showed that ceramic geopolymers can be made from kaolin with a low calcination temperature that have similar properties to those made from high calcined temperature. However, the choice of alkali activator and chemical composition should be carefully investigated, especially under normal curing conditions, 27 °C. A comprehensive review of the properties of kaolin ceramic geopolymers is also presented, including compressive strength, chemical composition, morphological, and phase analysis. This review also highlights recent findings on the range of sintering temperature in the ceramic geopolymer field which should be performed between 600 °C and 1200 °C. A brief understanding of kaolin geopolymers with a few types of reinforcement towards property enhancement were covered. To improve toughness, the role of zirconia was highlighted. The addition of zirconia between 10% and 40% in geopolymer materials promises better properties and the mechanism reaction is presented. Findings from the review should be used to identify potential strategies that could develop the performance of the kaolin ceramic geopolymers industry in the electronics industry, cement, and biomedical materials.

Optimizing Alkali-Concentration on Fresh and Durability Properties of Defected Sanitary Ware Porcelain based Geopolymer Concrete

“…A low-calcium-based geopolymer was found to have low permeability, a long setting time, less shrinkage and carbonation, and higher chloride resistance. Among common low-calcium precursors, the usage of porcelain and ceramic powder as precursors in the production of AAMs has already been reported in the literature [24][25][26][27][28][29]. Lowcalcium binder materials form and harden slightly when they cure at normal temperatures.…”

Improving Sag Resistance in Geopolymer Coatings Using Diatomite Filler: Effects on Rheological Properties and Early Hydration

“…The application of protective coatings to concrete surfaces is widely employed as a common method to prolong the lifespan of buildings and preserve the structural integrity of constructions within current engineering practices [ 9 , 10 , 11 , 12 ]. Geopolymer materials are a novel type of inorganic binder prepared through an alkali–silica/alumina reaction and are characterized by chemical resistance, strong adhesion, and environmental friendliness [ 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 ], making them highly applicable in the formulation of protective coatings for concrete surfaces. In recent decades, extensive research has been conducted on the practical application of geopolymer coatings [ 7 , 22 , 23 , 24 , 25 , 26 ], with sagging identified as one of the significant issues encountered in current applications.…”

Porous Geopolymer/ZnTiO3/TiO2 Composite for Adsorption and Photocatalytic Degradation of Methylene Blue Dye

“…There are several types of precursors, such as fly ash, kaolin, zeolites, rice hulls, etc. Of these, kaolin has a higher silicon and aluminum content, making it more suitable as a raw material for the synthesis of geopolymers [ 28 ]. Kaolin is a white non-reactive material that is composed of hydrated aluminum silicate, with a 1:1 structural ratio.…”