Valorization of ceramic sanitary waste into Resilient phosphoric acid-based geopolymers for sustainable construction: Thermal, mechanical, and microstructural properties

The construction industry's heavy reliance on conventional cement production contributes significantly to global carbon dioxide emissions, prompting the need for eco-friendly building materials. Geopolymers, synthesized from natural materials like clay and fly ash, offer a sustainable alternative to traditional cement. This paper investigates the development of phosphoric acid-activated geopolymers with sanitary ware waste (SWW) as aggregates, aiming to create high-performance, environmentally friendly building materials. Various particle sizes of SWW were incorporated into the geopolymer matrix, revealing a strong relationship between particle size and compressive strength. The inclusion of SWW improved compressive strength, with a notable 83 % increase at 30 % SWW content. Fourier transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD) analyses highlighted the formation of new bonds in the geopolymeric gel, while scanning electron microscopy (SEM) showed microcracks and good adhesion between SWW particles and the geopolymer matrix. Thermal resistance tests demonstrated that SWW-reinforced geopolymers exhibited improved resistance to high temperatures compared to the reference geopolymer. XRD analysis of thermally treated geopolymers revealed the transformation of amorphous phases into stable crystalline phases. SEM/EDX mapping confirmed the presence of silica-rich phases, contributing to the materials' mechanical properties and thermal resistance. This study underscores the potential of SWW-based geopolymers as sustainable, high-performance building materials.