Sustainable Manufacturing of High-Performance Ternary Geopolymer Composites Using Multi-Source Waste for Energy-Efficient Buildings

The research work presented an environmentally sustainable ternary geopolymer composite, which uses fly ash, waste foundry sand, and construction and demolition waste C&D as its base materials. The main goal of the study is to develop construction materials that effectively use energy- saving technologies during all building operations. In this study, six mix designs were developed with desired material combinations after testing different WFS and C&D material ratios while keeping fly ash levels constant to assess material strength and durability. The study also used statistical models to examine dry density, water absorption, compressive strength, impact resistance, and abrasion loss. The optimum mix consisted of 30% C&D waste (M3) on various parameters, such as the highest compressive strength of 38 MPa, the lowest water absorption of 7.2%, and increased impact resistance of 15%. The performance enhancement occurred due to the formation of N-A-S-H and C-A-S-H gels. The development occurred through the combination of silica obtained from waste foundry sand, together with calcium derived from C&D fines. The research demonstrates an effective multi-waste valorisation method that creates an environmentally sustainable production process while promoting circular economy principles through its efficient resource usage and low-carbon material production.