Optimizing mix design methods for using slag, ceramic, and glass waste powders in eco-friendly geopolymer mortars.

Faced with the urgent need to develop environmentally friendly alternatives to cementitious materials, geopolymers, made from combinations of various by-products, offer a promising solution. In recent years, statistical optimization methods have begun to be applied in the field of engineering. This study focuses on sustainable geopolymer mortars by incorporating industrial by-product powders, specifically blast furnace slag (SP), waste glass powder (GP), and ceramic powder (CP) as partial replacements. Compressive strength, flexural strength, workability, and density were evaluated for various ternary compositions using a Mix Design Model (MDM) approach. The main results revealed a synergistic interaction between SP and CP, with a 20% replacement of CP leading to a 16% increase in compressive strength, indicating optimal performance. Microstructural analysis using SEM, TGA, and FTIR highlighted a dense, crack-free matrix with extensive calcium aluminosilicate gel phases, particularly in the SP–CP mixture. Optimization through desirability profiling identified a 30% CP replacement as ideal for maximizing strength and workability. Controlled optimization of multi-component geopolymer synthesis using by-products streams proves to be a promising method for developing next-generation sustainable construction materials. [ABSTRACT FROM AUTHOR]