Effect of Sodium Silicate and Sodium Hydroxide Ratios on Compressive Strength of Ceramic Brick and Metakaolin Waste-Based Geopolymer Binder

The construction industry's growth is causing a surge in CO₂ emissions, driven by increased demand for concrete and other building materials. There is a growing demand for more sustainable building materials, including alkali-activated materials. This study investigates the impact of varying ratios of Na₂SiO₃ and NaOH on the mechanical properties and microstructure of metakaolin (MKW) and ceramic brick waste (CBW) based geopolymer binder. Geopolymer binder precursors were made of three main CBW/MKW ratios: 100/0%wt. (C100), 50/50%wt. (C50M50), and 0/100%wt. (M100). Alkaline activator solutions had three different Na₂SiO₃/NaOH ratios: 0.5, 1.0, and 2.0. The investigation into the geopolymer binder mechanical properties was conducted using a range of analytical methods, including compressive strength, scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FT-IR). The findings of the study indicate that the Na₂SiO₃/NaOH ratio alone is inadequate for evaluating geopolymer mechanical properties when different AS/P ratios are employed, given its influence on other parameters, such as the W/S ratio and the total Na₂O content. CBW-based geopolymer binders demonstrate limited capacity to attain substantial compressive strengths because they contain high amounts of unreacted CBW particles, as shown by XRD analysis. The incorporation of MKW precursor resulted in enhanced reactivity and intensified geopolymerization reaction. After the evaluation of all essential ratios, the most favorable Na₂SiO₃/NaOH ratio is 1.0. This determination was based on the highest strengths observed in designs that contained ≥50% of MKW precursor, attributed to predominance of goosecreekite and N-A-S-H gels, as evidenced by XRD and FT-IR analysis.