Facile construction of porous epoxy resin/geopolymer composites using red mud and slag by well-distributed dual-blending

Porous geopolymer composite (E51) reinforced by E51 epoxy resin was prepared by well-distributed dual-blending using red mud, metakaolin, and slag as raw materials. The effects of E51 content on microstructure, porosity, mechanical properties, and thermal insulation properties of the porous composites were investigated. The addition of E51 changed the setting time and viscosity of the slurry with high content of solid wastes (80%), which play an important role in the formation of pores during the direct foaming process. The addition of E51 had great influence on the porous properties of geopolymer composites, which in turn affected their compressive strength (0.19–1.44 MPa) and thermal conductivity (0.09–0.12 W/mK). The addition of E51 enabled the production of geopolymer composites in a rather large range of total porosity (67.3–81.1 vol%), with an optimal sample possessing a total porosity of up to 78.7 vol%, a thermal conductivity of 0.086 W/mK, and a compression strength of 0.47 MPa. © 2024 The Author(s). International Journal of Applied Ceramic Technology published by Wiley Periodicals LLC on behalf of American Ceramics Society.