Automating sustainable manufacturing: optimizing eco-friendly geopolymer bricks with plastic waste and curing conditions

This research examines the influence of plastic waste, curing conditions and durations on geopolymer bricks, providing valuable insights for the development of environmentally friendly building materials. This study investigates the impact of plastic waste (PW) incorporation, curing conditions and duration on the performance of geopolymer bricks, offering insights into their potential as sustainable building materials. The results indicate that increasing plastic content reduces compressive strength, while higher curing temperatures (30–70 °C) significantly enhance strength by 56%. The incorporation of PW leads to greater water absorption, which is positively correlated (39%) with thermal conductivity and negatively correlated (42%) with compressive strength. Microstructural analysis using scanning electron microscopy (SEM), X-ray diffraction (XRD) and Fourier transform infra-red spectroscopy (FTIR) reveals the formation of voids, fractures and alterations in bonding structure, which influence mechanical performance. Additionally, thermal conductivity improves by up to 25% as PW substitution increases from 0% to 100%, presenting potential benefits for thermal regulation in construction. These findings provide a foundation for optimising geopolymer bricks, demonstrating their environmental benefits and feasibility as an eco-friendly alternative to traditional masonry materials.