The aim of the article is to analyze the structure and mechanical properties in terms of the cracking mechanics of geopolymer composites based on fly ash and river sand, as well as metakaolin and river sand with three types of reinforcement material: glass fiber, carbon fiber, and aramid fiber, in terms of their use in additive manufacturing. Geopolymer composites were reinforced with fibers in a volume ratio of 0.5%, 1.0%, and 2.0%. Subsequently, these samples were subjected to bending strength tests in accordance with the European standard EN 12390-3. The addition of fibers significantly improved the bending strength of all composites made of metakaolin and sand. The reinforcement with aramid fiber in the amount of 2.0% resulted in more than a 3-fold increase in strength compared to the reinforcement-free composites. An analysis of the morphology of the fibers was carried out on the basis of photos taken from an electron microscope. The correct addition of fibers changes the nature of the fracture from brittle to more ductile and reduces the number of cracks in the material.

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 article shows the possibility of using industrial and mining waste for creating new eco-friendly materials – geopolymers. The main objective of the article is to analyze the possibilities of using new composite received from waste materials from mining industry in practical applications, especially in construction industry. The article presents benefits and potential threats for using wastes for production of geopolymers from gangue, waste from iron processing, waste from copper mining and processing, waste from chromium processing and so-called red mud from aluminum production. Research methods applied in the article are: critical analysis of literature sources, including comparison new material with other materials used in similar applications.

The main purpose of the article is to present the differences in the parameters of geopolymer foams obtained in the same way, which is associated with difficulties in controlling the foaming process. Difficulties in controlling the foaming process of geopolymers are the direct reason for the lack of implementation of such materials nowadays. The article shows the results for experimental research, especially research into insulation, physical, and mechanical properties for the designated foamed materials. Microspheres (75%), sand (5%) and fly ash (20%) were used to produce foamed geopolymers. Hydrogen peroxide was the foaming agent. Heat conduction coefficients of 0.08-0.07 W/mK were obtained. The material density was obtained at the level of 363-375 [kg/m3] and the compressive strength was 520-683 [kPa]. The results showed that geopolymers can be a good alternative to conventional insulation materials, but the foaming technology should be developed so that it is stable and allows for reproducible material parameters.

Two geopolymer foams were prepared from a thermally activated coal gangue containing kaolinite. As the foaming agent, aluminium powder and 36% hydrogen peroxide were used to obtain two levels of porosity. The materials’ high temperature performances were investigated: tensile and compressive strength evolution with temperature. This study shows that the mechanical performances of developed geopolymer foams are similar to foam concrete of the same apparent density. The geopolymer foams from coal gangue present stable mechanical performances up to 600 °C. When the glass transition temperature is achieved, sintering occurs and mechanical performance increases. SEM observations confirm the glass transition and densification of the matrix at temperatures above 800 °C. Moreover, the XRD measurements revealed a high amount of mullite that forms at 1000 °C that explained the observed strength increase. The synthesis of good-quality geopolymer foams from coal gangue and its application as a thermal barrier is feasible. The constant level of porosity and its stable character in the range of temperatures 20–1000 °C ensures stable thermal insulation parameters with increasing temperature, which is extremely important for fire protection.