Development and optimization of an eco-friendly geopolymer brick production process for sustainable masonry construction

Geopolymer has emerged as an alternative material in construction. The prime objective of this investigation is to produce high-quality and eco-friendly geopolymer bricks. The current research involves a detailed analysis of the sustainability study of geopolymer bricks, which includes investigating the effects of granite waste powder and iron chips on structural properties. Additionally, economic analysis through a linear programming model is investigated.Geopolymer brick was prepared with size 190 x 90x90 mm, and the weight as 3 kg, activator agent as sodium hydroxide solution with 10 M, and alkaline-to-binder ratio of 2.5, specimens were cast at ambient condition, mechanical properties were of casted sample were tested at 7 and 28 days.It was found that the SIC3 mix has a higher embodied energy and carbon emission value than FGG1 and FGG2. FG5-mix showed maximum compressive strength and water absorption of 10.1 MPa and 16.8%, respectively, with an optimum percentage of granite waste powder and iron chip of 20%. The prism unit for 1:3 showed maximum compressive stress compared to 1:4 and 1.5. Furthermore, using Scanning Electron Microscopy, the specimen with granite waste powder and iron chip showed slightly lamellar and granule-covered surfaces. When X-Ray diffraction analysis images were studied, peaks responsible for geopolymerization were identified, and their impact on geopolymer properties was discussed. Geopolymer brick shows better structural performance compared with burnt clay and flyash brick.