Geopolymer: A Systematic Review of Methodologies

The geopolymer concept has gained wide international attention during the last two decades and is now seen as a potential alternative to ordinary Portland cement; however, before full implementation in the national and international standards, the geopolymer concept requires clarity on the commonly used definitions and mix design methodologies. The lack of a common definition and methodology has led to inconsistency and confusion across disciplines. This review aims to clarify the most existing geopolymer definitions and the diverse procedures on geopolymer methodologies to attain a good understanding of both the unary and binary geopolymer systems. This review puts into perspective the most crucial facets to facilitate the sustainable development and adoption of geopolymer design standards. A systematic review protocol was developed based on the Preferred Reporting of Items for Systematic Reviews and Meta-Analyses (PRISMA) checklist and applied to the Scopus database to retrieve articles. Geopolymer is a product of a polycondensation reaction that yields a three-dimensional tecto-aluminosilicate matrix. Compared to unary geopolymer systems, binary geopolymer systems contain complex hydrated gel structures and polymerized networks that influence workability, strength, and durability. The optimum utilization of high calcium industrial by-products such as ground granulated blast furnace slag, Class-C fly ash, and phosphogypsum in unary or binary geopolymer systems give C-S-H or C-A-S-H gels with dense polymerized networks that enhance strength gains and setting times. As there is no geopolymer mix design standard, most geopolymer mix designs apply the trial-and-error approach, and a few apply the Taguchi approach, particle packing fraction method, and response surface methodology. The adopted mix designs require the optimization of certain mixture variables whilst keeping constant other nominal material factors. The production of NaOH gives less CO2 emission compared to Na2SiO3, which requires higher calcination temperatures for Na2CO3 and SiO2. However, their usage is considered unsustainable due to their caustic nature, high energy demand, and cost. Besides the blending of fly ash with other industrial by-products, phosphogypsum also has the potential for use as an ingredient in blended geopolymer systems. The parameters identified in this review can help foster the robust adoption of geopolymer as a potential “go-to” alternative to ordinary Portland cement for construction. Furthermore, the proposed future research areas will help address the various innovation gaps observed in current literature with a view of the environment and society.