Performance of Geopolymer Insulation Bricks Synthesized from Industrial Waste

In the current work, aluminum dross from the aluminum industry and fired-clay brick waste (Homra) were combined with alkaline activators (Na2SiO3/NaOH) with varying molarities of NaOH to create insulating geopolymer bricks. An alkaline activator with an (S/L) ratio of 3/1 was combined with Homra to replace it partly. The mixture was then molded into 50 × 50 × 50 mm3 stainless steel molds. Water absorption, compressive strength, bulk density, and apparent porosity of the produced geopolymer were measured at various curing durations and NaOH molarities. The findings showed that adding more aluminum dross waste replacement leads to a decrease in bulk density and compressive strength and an increase in the creation of pores that improve the produced bricks’ ability to insulate against heat. Using 8 M of NaOH after 28 days, the findings revealed that 3% aluminum dross waste replacement has a compressive strength of about 8.6 MPa, water absorption of 14.6%, bulk density of 1.307 g/cm3, and thermal conductivity of 0.32 W/m·K. The Egyptian standard, ASTM C62, satisfies these outcomes. Using DesignBuilder energy simulation software version 6.1.06, the constructed insulating brick under ideal circumstances was utilized to calculate its contribution performance in energy consumption. The annual energy consumption was reduced by about 21% compared to traditional hollow cement bricks.