Open Access Article
Rodrigue Cyriaque Kaze
*abc,
Joël Donkeng-Dazie
a,
Abdolhossein Naghizadehb and
Mohend Chaouchec
aSchool of Chemical Engineering and Mineral Industries (EGCIM), Department of Material Engineering, University of Ngaoundéré, P. O. Box 454, Ngaoundéré, Cameroon. E-mail: kazerodrigue@gmail.com
bDepartment of Engineering Sciences, University of the Free State, Bloemfontein, 9300, South Africa
cUniversité Paris-Saclay, CentraleSupélec, ENS Paris-Saclay, CNRS, LMPS – Laboratoire de Mécanique Paris-Saclay, 91190, Gif-sur-Yvette, France
First published on 23rd March 2026
In this study, the effects of micro- and nano-sized iron powders, as well as the mixing procedure, on the fresh and hardened properties of metahalloysite-based geopolymer composites were investigated. Iron powders were incorporated at dosages of 2, 4, and 6 wt% of the binder, and two distinct mixing procedures were adopted for specimen preparation. In the first procedure, metahalloysite was dry-blended with the iron powder prior to the addition of the alkaline activator. In the second procedure, the iron powder was first dispersed in the alkaline solution, after which metahalloysite was gradually introduced into the mixture. Afterwards, the resulting paste samples were subjected to mechanical properties evaluation. Furthermore, both the raw materials and the synthesised binders were characterised in terms of phase composition and microstructure using Fourier-transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), and scanning electron microscopy (SEM). The results indicated that compressive strengths of 55 and 58 MPa were achieved with the addition of 2 wt% nano-sized and 6 wt% micro-sized iron powder, respectively, when the first mixing procedure was applied. In contrast, for the second procedure, compressive strengths of 55 and 56 MPa were obtained at the corresponding iron powder contents. Overall, the findings suggest that nano-sized iron powder can effectively enhance the mechanical performance of geopolymer composites. The relatively high strength observed in specimens incorporating micro-sized iron powder is attributed to a filler effect that promotes pore refinement and results in a more compact, denser microstructure. Conversely, pre-dissolution of iron powder in the alkaline solution prior to the addition of metahalloysite was found to hinder the geopolymerisation reaction and the development of a well-connected geopolymer network, resulting in reduced compressive strength.
The previous studies on metahalloysite-based geopolymer in the literature have mostly focused on the mix proportion,9–11 varied heating temperature ranging between 450 and 850 °C,12 curing temperature range of 20–80 °C,13 concentration of alkaline14,15 or acidic16,17 solutions. Several studies have reported that employing the optimal temperature of 750 °C resulted in better performance.7,8,18 Recent developments in nanomaterials have made the use of such materials in enhancing geopolymer's mechanical and microstructural properties.19 Various nanoparticles such as carbon nanotubes (CNTs), nano-silica, and nano-alumina have been widely incorporated into polymer and geopolymer composites to enhance mechanical performance, durability, and microstructural stability. These nanomaterials can improve matrix densification, crack resistance, and interfacial bonding within the composite structure.20–23
Some studies showed that the early and later age strengths of geopolymer pastes,24 mortars, and concretes25 improved when a small amount of nanomaterial powder, such as nano silica, alumina, or iron, was used. The reported effect of nanomaterials was attributed to accelerated cement hydration26 and pozzolanic reaction,26 reduced pores,27 and enhanced interface bonding between binder phase and aggregates.28 For example, Mohamed et al.24 reported that the inclusion of nano rutile or anatase powders in mixtures increased the 28-day flexural strength of metahalloysite-based geopolymer pastes.
Nongnuang et al.29 observed an improvement in the mechanical properties of a high-calcium fly ash-based geopolymer due to inclusion of up to 20 wt% waste iron powder (WIP) in the mixtures. It was reported that fly ash-based geopolymer binder containing 20 wt% WIP gave 28-day flexural strength of 8.5 MPa, which was almost three times higher than the reference mixture that was made without WIP addition. Khouadjia et al.30 investigated the rheological behaviour and mechanical properties of volcanic tuff-based geopolymer blended with WIP up to 20 wt%. Results revealed that air content in the binder matrix increased to 3.5% with 20% iron powder (IP) substitution, accompanied by a slight rise in flow time (0.8–2 s). While the compressive strength and flexural strengths at 25 °C decreased by up to 22.48% and 28.39%, respectively. However, the compressive and flexural strengths almost doubled when the samples were oven-cured at 80 °C. Prałat et al.31 evaluated the thermal parameters of geopolymer products modified with IP. They reported that introducing IP led to significant changes in their thermal properties, including thermal conductivity, specific heat, and thermal diffusivity. Wu et al.32 produced Fe-based geopolymers by adding hematite (HE), magnetite (MA), and reduced iron powder (RIP) into metakaolin powder (MK) up to 20 wt% and evaluated their influence. They reported that RIP did not significantly reduce the strength of the geopolymer, maintaining performance close to that of the reference (geopolymer without additive), compared with HE and MA additives. Table 1 provides a summary of the parameters influencing the end properties of geopolymer blended with different iron mineral sources, as reviewed in the literature. All of these reviewed experiments include substituting precursor materials with iron minerals from various sources and then adding an alkaline solution activator to assess their effect on geopolymer characteristics. The unique aspect of this work is that it assesses the influence of mixing in order to understand the behavior of ferrous minerals in the geopolymer matrix. This would contribute to the literature on the role of minerals in the synthesis of geopolymers.
| Raw materials | Iron source | Activator | Curing regime | Obtained results |
|---|---|---|---|---|
| Metakaolin33 | Ferric ions solution (10, 20, 30, 40 and 50 mL) | Sodium silicate | Room temperature | 71.59 MPa was achieved using 13.2 mL of Fe3+ and 20 mL of sodium silicate |
| Metakaolin34 | Ferric ions (5, 10, 15 and 20 g) | Sodium silicate | Room temperature | 72.80 MPa was attained by replacing the metakaolin with 5 g of ferric ions |
| Volcanic tuff35 | Iron powder (IPW) waste at percentages of 5%, 10%, and 20% | Sodium silicate gel (SS) with SiO2 and Na2O contents of 28.8% and 14.2% | Two curing time temperatures of 25 °C and 80 °C for 24 h | The use of iron powder reduces the compressive strength by a percentage of 2.82%, 2.01%, and 22.479% for samples blended with 5, 10 and 20% IPW cured at 25 °C and, 49.79%, 30.84%, and 47.37% for those cured at 80 °C |
| Metakaolin36 | Hematite, magnetite and goethite (5, 10 and 20 of each iron mineral) | Sodium silicate | Room temperature | 55 MPa achieved on samples with 10% of hematite |
| Waste fired clay brick and metakaolin37 | Hematite and rice husk ash (0 and 10 wt%) | Sodium silicate (Ms = 1.6) | Room temperature | For the metakaolin-based geopolymers the compressive strength increased from 53.34 to 69.08 MPa when the Fe2O3/SiO2 increased from 0 to 0.8 |
| Those of geopolymer materials derived from waste fired clay brick decreased from 45.42 to 21.15 MPa when their Fe2O3/SiO2 molar ratios rise from 0 to 0.6 increases from 21.15 to 24.11 MPa beyond 0.6 | ||||
| Metakolin32 | Hematite, magnetite and raw iron powders (2, 5, 10 and 20%) | Sodium silicate (Ms = 1.5) | 20 °C | 5% of hematite and raw iron gave the highest strength 65 MPa whereas no any increases was observed on samples blended with raw iron powder |
| Fly ash38 | Waste iron powder (10 and 20%) | Sodium silicate | Room temperature | 62.79 MPa achieved on sample blended with 20% of waste iron powder |
| High calcium fly ash39 | Waste iron powder (5, 10, 15 and 20%) | Sodium silicate | Oven curing between 30 °C and 60 °C for 24 h | 20% of iron powder ensured the highest strength of 50.5 MPa, which was approximately 76% of the strength of the control |
| Kaolin-zeolite40 | Micro Fe2O3 (4, 6, and 8%) | NaOH-based activator containing 15% Na (Na/binder) by weight | Cured at 110 °C for 24 h using a furnace | Kaolin based geopolymer blended with 8% of micro iron powder was 5% higher than sample reference |
| Fly ash41 | Iron ore tailing (10, 20 and 30%) | Sodium silicate | 20 ± 2 °C and 90 ± 5% relative humidity | 50 MPa achieved on sample blended with 20% of iron ore tailing |
| Slag42 | Hematite (5, 10 and 15%) | Sodium silicate (Ms = 1.8) | Oven cured at 60 °C for 8 h | Replacing slag with hematite decreased the compressive strength from 73.6 to 32.46 MPa |
| Slag43 | Iron filling (IF) obtained from iron local mechanical workshops (10, 20, 30, 40 and 50 wt%) | Sodium silicate (Ms = 2) | Room temperature | 10% IF replacement ratio showed the highest values of 39 and 6.2 MPa for compressive and flexural strength with an increase of 12.1% and 25.5% respectively compared to the control mixture |
| Volcanic ash44 | 0, 5, 10, 15, and 20% iron waste powder residues from a welding shop on the properties of PIPs | H3PO4 (6 M) | Room temperature | Iron powders can be used as a pore-forming agent as observed in the decrease of compressive strength from 28 to 2 MPa |
In the majority of previously reported studies, iron powder was incorporated by direct blending with solid precursors, without systematically considering the effects of particle size or the dispersion of iron powder in the alkaline activator. In contrast, the present study uniquely combines and compares two distinct incorporation approaches: (i) partial substitution of metahalloysite with micro- and nano-sized iron powders at levels of 0, 2, 4, and 6 wt%, and (ii) pre-dispersion of iron powder in the alkaline solution prior to the addition of the solid precursor. This dual approach enables a systematic evaluation of the influence of both particle size and mixing procedure on the fresh and hardened properties of metahalloysite-based geopolymer composites. Furthermore, the study focuses on the effects of iron powders on the setting time and later age (28 days) strengths of geopolymer mixtures, using iron powders composed of micro- and nano-particles in comparison. As iron particles are very fine and tend to agglomerate due to strong surface interactions, the effects of dispersion methods for iron powders were also investigated by dissolving the powders in an alkaline solution before introducing them into metahalloysite powder. In addition to compressive strength and setting time, the flowability of the mixtures was also studied and compared. The study provides information for systematic analyses on: (i) the effect of iron powder content, (ii) the effect of particle size of the iron powder, and (iii) the effect of dispersion methods on the properties of metahalloysite-based geopolymer binders.
:
2, as selected from a previous study.7 Two types of iron powders were used: micro and nano, with particle diameters of −200 mesh (74 µm) and 50 nm, respectively. These iron powders were supplied by Alfa Aesar (micro iron powder) and Nanofer Star (nano iron powder). Two mixing procedures were employed for the synthesis of the geopolymer composites. In the first procedure, metahalloysite was dry-mixed with 2, 4, and 6 wt% iron powder, after which the alkaline activator was added at a solid-to-liquid ratio of 0.8. The mixture was then mechanically stirred at 1000 rpm for 3 min. The selected solid-to-liquid ratio was determined through preliminary trial mixes to achieve adequate workability of the fresh geopolymer paste. In the second mixing procedure, different iron powders were mixed with an alkaline solution for 30 seconds before adding the metahalloysite powder. Both procedures produced fresh geopolymer composite pastes, which were poured into 20 mm cubic moulds, and stored in room temperature. After 24 hours, the moulds were demoulded and maintained at room temperature until a mechanical test was performed 28 days later. The mixture proportions of the geopolymer pastes containing micro- and nano-iron powders are given in Table 2.
| ID | Calcined halloysite (g) | Micro or nano iron powder (g) | Alkaline solution (g) |
|---|---|---|---|
| GMPH0 | 100 | 0 | 80 |
| GPMH2 | 98 | 2 | 80 |
| GPMH4 | 96 | 4 | 80 |
| GPMH6 | 94 | 6 | 80 |
The functional groups within raw materials and geopolymers were identified with a Bruker Vertex 80v infrared spectrometer using the KBr technique, the pellet from each sample was used for 32 scans at a resolution of 2 cm−1. About 1.2 mg of the sample and 200 mg of KBr were combined to make each pellet.
The fresh geopolymer pastes were subjected to workability measurements immediately after mixing. A small cone with a bottom diameter of 38 mm, a top diameter of 19 mm, and a height of 57 mm was used for workability measurements, in accordance with previous research.45,46
Compressive strength was determined using hardened geopolymer paste cubes. Mechanical testing was performed with an Instron® 5965 universal testing machine under a constant displacement rate of 3 mm min−1. The reported compressive strength, water absorption, porosity and bulk density values represent the average of five specimens tested for each geopolymer formulation. In addition, water absorption, apparent porosity, and bulk density were measured using an electronic balance (Sartorius, model 1712001) with a sensitivity of ±0.001 g, in accordance with the Archimedes principle. Prior to these measurements, the specimens were oven-dried at 40 °C until a constant mass was achieved.
Fig. 2 displays the FTIR spectra of calcined halloysite along with micro- or nano-iron materials. In the case of metahalloysite powder, the broad band appearing at 3440 and 1625 cm−1 is assigned to vibrational modes of O–H belonging to the residual halloysite mineral.9 The persistence of these absorption bands suggests that they are not fully transformed into metahalloysite. The broad absorption bands appearing at 1096 cm−1 are assigned to the asymmetric stretching band of Si–O–Al, attributable to the amorphous phase related to the transformation of halloysite mineral into metahalloysite.8,48 The absorption bands located at 797, 694, 456 and 395 cm−1 are assigned to asymmetric stretching vibrations of Si–O related to quartz mineral.49,50 For the iron powders, the absorption bands appearing at 3440 and 1625 cm−1 (Fig. 2b) are assigned to stretching bonds of surface water molecules or to an envelope formed by hydrogen-bonded surface OH groups.51,52 The absorption bands at 1120, 1123, and 1048 cm−1 are assigned to C–O stretching vibrations (Fig. 2b and c).53 Finally, the absorption bands at 797, 694, 668, 589, 456, and 395 cm−1 are assigned to the Fe–O stretching vibration mode (Fig. 2b and c).54–56
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| Fig. 3 Flow values of fresh geopolymer pastes blended with micro and nano iron powders applying procedure mix I (a and c) and II (b and d). | ||
Fig. 4 presents the initial setting times recorded for a fresh metahalloysite-based geopolymer blended with micro- and nano-iron powders at varying dosages (0, 2, 4, and 6 wt%). For the first mixing procedure, the initial setting decreased from 240 to 225 min for samples blended with micro-iron powder and from 240 to 215 min for those blended with nano-iron powder. The reduced setting may be associated with possible interaction between iron species (e.g. Fe3+ and Fe2+) and alkaline solution, which may react with HO− to form Fe(OH)3 and Fe(OH)2 (eqn (2) and (3)). Furthermore, in the highly alkaline environment these iron hydroxides compounds can be dissolved to form FeO2− and FeO22−, respectively thereby reducing the setting time. However, it should be noted the present study does not directly quantify Fe dissolution or speciation. Therefore, the role of Fe3+/Fe2+ species in modifying the geopolymerisation kinetics should be considered as a potential mechanism rather than a confirmed reaction pathway. In samples incorporating the micro-iron powder with high particle size, the homogeneity of the geopolymer binder within the matrix was improved, accelerating setting and resulting in the lower setting time recorded. The increased initial observed in the second mixing procedure was likely due to the dissolution of both iron powders into the alkaline solution. Their dissolution reduced the alkaline and then affected the dissolution of calcined halloysite. In fact, the in situ dissolution of both iron powder types generated more nucleic sites in different geopolymer mixtures, affecting the workability and progressively delaying the setting time. In addition, the slight increase recorded between GPMH4 and GPMH6 samples (Fig. 4a) might be attributed to the competitive environment created between the nano iron powders with metahalloysite. The nano iron powders in contact with the alkaline solution will release more iron with FeO2− and FeO22− species in alkaline medium interacted with Na+ to form 2NaFeO2 and Na2FeO2 compounds as described in eqn (1). This would limit the availability of Na+ cations needed for balancing the negative charge within the geopolymer framework prolonging the setting time with a little longer condensation or polymerisation process. This adverse effect impeded the creation of long polymerization chains and augmented the pore diameter and shape of the final geopolymer material post-geopolymerization, hence diminishing its compressive strength development.
| Fe3O4 + 4NaOH → 2NaFeO2 + Na2FeO2 + 2H2O | (1) |
| Fe(OH)3 + NaOH → NaFeO2 + 2H2O | (2) |
| Fe(OH)2 + 2NaOH → Na2FeO2 + H2O + H2 | (3) |
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| Fig. 4 Initial setting time of geopolymer binders blended with micro and nano iron powders using the first (a) and second (b) mix procedures. | ||
The FTIR spectra of calcined halloysite (MHA) and geopolymer blended with 0, 2, 4 and 6 wt% of micro and nano iron powders are shown in Fig. 6. It can be observed that the broad absorption bands at 1649, 3458, 3459, 3467, 3466, 3461, 3470, and 3473 cm−1 are assigned to stretching vibrations of water molecules within the geopolymer network.61 The broad at 1096 cm−1 on MHA spectrum shifted towards lower frequency after alkaline action; 1024 cm−1, 1015 cm−1, 1017 cm−1 and 1022 cm−1 for GPMH0, GPMH2, GPMH4 and GPMH6 blended with micro iron powders at varied dosages (Fig. 6a). In case of geopolymer samples blended with nano iron powders this band shifted to 1010 cm−1, 1017 cm−1 and 1018 cm−1, respectively (Fig. 6b). This behaviour is likely attributed to stretching vibrations modes of Si–O–Al of geopolymer network.49 The last bands observed at 778, 694, and 456 cm−1 are attributed to the stretching vibration modes of Si–O–Si, Si–O–Al, and Al–O.62–64 Finally, the XRD and FTIR analyses did not point out any changes. This could be attributed to the milling effect of hardened geopolymer samples cured at 28 days which ground and sieved under 75 µm before running the measurement. Hence running these analyses in situ on the fresh geopolymer pastes blended with both iron powders should be hopeful for more clarity. Furthermore, XRD results also showed the reflection peaks of magnetite suggesting their none total dissolution which could act as inactive granular fillers through the presence of unreacted phases in geopolymer binder specimens as reported in ref. 40.
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| Fig. 6 Infrared spectra of calcined halloysite (MHA) and geopolymer blended with 2, 4 and 6 wt% of micro (a) and nano (b) iron powders. | ||
However, when the nano-iron powder content exceeded 4 wt% (Fig. 7b), a significant reduction in compressive strength was observed. This behaviour may be attributed to excessive iron species formed in the alkaline medium, which can interact with Na+ ions and reduce their availability for balancing the negative charges within the geopolymer framework.35 As a result, the condensation and polymerisation processes may be hindered, leading to the formation of a less compact matrix and consequently lower compressive strength.36
For specimens prepared using the second procedure (in situ mixing of the alkaline activator with micro- and nano-iron powders), the incorporation of 2 wt% micro-iron powder and 4 wt% nano-iron powder resulted in the highest compressive strengths of 56.03 MPa (Fig. 8a) and 55.63 MPa (Fig. 8b), respectively. This strength enhancement is consistent with previous studies suggesting the possible formation of iron–silicate interactions within geopolymer systems.32,65,66 The reduction in strength observed beyond these optimum dosages might be associated with the excessive dissolution of iron powder under alkaline conditions, leading to an increased concentration of iron ions that can interfere with the geopolymerisation process and hinder the development of a well-connected aluminosilicate network. Furthermore, during the in situ mixing process, a portion of the alkaline activator could be consumed through reactions with the iron particles, thereby limiting the effective dissolution of metahalloysite and negatively affecting strength development. It is worth noting that in the present study, the available characterisation techniques do not provide direct evidence of Fe incorporation into the geopolymer gel structure. Therefore, the observed improvement in mechanical performance may primarily arise from physical effects such as particle packing and micro-filler action, while potential chemical contributions of Fe species remain speculative and require further investigation.
Also, the results indicate that, at their optimum dosages, micro- and nano-iron particles act as reaction accelerators and micro-fillers, promoting a denser packing of the matrix and leading to the development of a strong and compact geopolymer structure.67,68 The decrease in compressive strength (Fig. 8a and b) observed in geopolymer samples when added 4 and 6% of both iron powders in the second procedure could be attributed to the iron(II) dioxo ion, FeO22− (eqn (3)) which is more pronounced in nano than micro powders. Finally, the release of H2 during the premixing would provide the air bubbles as seen in the matrix, which are detrimental for the strength development, demonstrating the optimum at 2% of both iron powders added.
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| Fig. 9 Water absorption, porosity and bulk density values of metahalloysite based geopolymer composites blended with nano and micro Fe3O4 powder applying procedures I (a and b) and II (c and d). | ||
For samples prepared using the second procedure (Fig. 9c), water absorption and apparent porosity ranged from 26.5–28.5% and 38.02–43.5%, respectively, for mixtures containing micro-iron powder. For those incorporating nano-iron powder (Fig. 9d), the corresponding ranges were 24.80–27.50% and 36.80–43.50%. The bulk densities obtained from both procedures were within a similar range of 1.68–1.82 g cm−3 and 1.68–1.83 g cm−3, respectively. It is noteworthy that porosity and water absorption followed comparable trends and exhibited similar magnitudes regardless of the mixing procedure. However, iron dosages exceeding 4 wt% were found to be detrimental, as excess particles are unlikely to effectively participate in the geopolymerisation process. This leads to the formation of a less compact matrix with increased open voids and pore connectivity, which promotes higher water uptake during testing. Conversely, the incorporation of iron powder at optimum levels contributes to progressive matrix densification and reduced porosity. Previous studies also reported the increase in bulk density of hardened geopolymer binders with the increased iron powder from different sources.35,39,71,72 These authors claimed that the increase in bulk density is owing to the filler effect of micro or nano iron powders used, resulting in densified geopolymer specimens with less open voids.
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| Fig. 10 SEM images (10 µm) of geopolymer blended with 0, 2, 4 and 6 wt% of micro iron powder (a–d) and nano-iron powder (e) from first procedure. | ||
Fig. 11 presents SEM micrographs of reference geopolymer mixture (Fig. 11a) along with those made using micro- (Fig. 11b) and nano-iron powders (Fig. 11c–e) at various dosages, prepared using the second procedure in which the iron powders were first dispersed in the alkaline activator prior to the addition of calcined halloysite. The microstructures appear more homogeneous in samples containing nano-iron powder than in those with micro-iron powder, indicating the higher dissolution rate of nano-sized particles in the alkaline medium. The pre-dissolution of iron powders in the alkaline solution promotes improved dispersion within the geopolymer matrix and enhances cohesion between the reaction products. As mentioned in the foregoing, observed improvement in the binder matrix may be attributed to a combination of mechanisms. One possible contribution is the formation of iron–silicate (ferri-/ferro-silicate) interactions within the geopolymer matrix, which could contribute to matrix reinforcement and improved mechanical performance. In addition, the fine particle size of the iron powders may also promote a packing or filler effect, leading to a denser binder matrix. Further studies using advanced characterization techniques would be required to confirm the relative contribution of these mechanisms. However, iron contents beyond the optimum level were found to be detrimental to strength development. This can be attributed to excessive consumption of the alkaline activator by the dissolved iron species, leaving insufficient alkalinity to effectively dissolve the calcined halloysite. As a result, a less compact and poorly densified structure is formed.
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| Fig. 11 SEM images (10 µm) of geopolymer blended with 0, 2, 4 and 6 wt% of micro iron powder (a–d) and nano-iron powder (e) from the second procedure. | ||
At an addition level of 2 wt% for both micro- and nano-iron powders, the micrographs reveal the presence of numerous nucleation sites favourable for geopolymerisation, promoting enhanced polycondensation between Al, Si, and Fe species and resulting in a stronger matrix (Fig. 11b and c). In contrast, higher dosages led to the appearance of microfissures and pores within the matrix (Fig. 11d and e), consistent with the observed reduction in compressive strength.
• Flowability decreased with increasing iron powder content due to the associated rise in mixture viscosity.
• Under procedure I, the incorporation of micro-iron powder up to 6 wt% resulted in the highest compressive strength (57.92 MPa), outperforming nano-iron powder. This behaviour is attributed to the filler effect of the coarser particles, which enhances matrix densification.
• Under procedure II, the addition of 2 wt% of either micro- or nano-iron powder provided the most favourable matrix cohesion and strength development.
• Iron powder contents exceeding the optimum level (2 wt% for procedure II) were detrimental to strength, primarily due to reduced workability and excessive consumption of the alkaline activator, which limited effective geopolymerisation.
• Geopolymers produced using procedure II consistently achieved compressive strengths above 40 MPa, indicating their suitability for structural and engineering applications.
• SEM observations confirmed that samples incorporating iron powders exhibited a more compact and densified microstructure compared with the reference geopolymer, with the degree of densification strongly influenced by the mixing procedure.
• Overall, both micro- and nano-iron powders can be effectively utilised at low dosages to enhance the performance of metahalloysite-based geopolymer binders, provided that the mixing procedure and iron content are carefully optimised to avoid adverse effects on geopolymerisation and strength development.
• The final products developed compressive strengths exceeding 48 MPa, indicating their potential use as construction materials for engineering applications such as road pavements and building components, while aligning with sustainable construction principles by reducing reliance on energy-intensive cement production.
Notwithstanding the enhanced performance of the developed geopolymer composites, further investigation using advanced spectroscopic techniques such as XPS, Mössbauer spectroscopy, SEM-EDS mapping, or ICP-OES would be required to directly determine the dissolution behaviour of Fe species and their possible incorporation into the geopolymer gel phase.
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