The acceleration of urbanization has been accompanied by the production of a large amount of construction waste [1]. Construction waste in China experienced a dramatic rise from 0.47 billion tons in 2006 to 3.2 billion tons in 2021, with projections suggesting that the total amount could surpass 4 billion tons by 2026 [2]. Engineering muck (EM), a major component of construction waste, is primarily generated by underground construction activities, such as tunnelling and the construction of underground facilities [3]. EM typically accumulates rapidly over a short period because of limitations in processing technology, which poses challenges to large-scale development and utilization. Currently, the most common treatment method for the EM is direct disposal, which includes landfill, marine landfill and subgrade filling. Among these methods, landfill disposal in waste dumps remains the most common approach due to low cost and convenience [4].
Improper geotechnical risk management at landfill sites can lead to severe safety issues. A typical example is the catastrophic 2015 geotechnical landslide at a landfill site in Shenzhen, China, where the collapse consisted more than 100,000 m3 of the EM, resulting in significant casualties and economic losses [5]. Additionally, landfill disposal of the EM can occupy a large number of valuable land resources, resulting in urban land shortage, especially in large cities. In the practice of geotechnical engineering, the subgrade is usually backfilled with the EM with good performance [6]. However, in 2024, under the influence of heavy rainfall, a highway pavement collapse occurred in Meizhou, China, caused by the landslide of EM, resulting in the death of 48 people. This tragic event caused widespread concern and deep social reflection.
Although the EM has high strength in its natural state, long-term weathering can cause the rock to become loose and the material more porous. Once the water penetrates, the bearing capacity and shear strength would decrease sharply, thus increasing the potential risk of such geotechnical engineering [7]. In view of this, traditional landfill disposal or subgrade filling methods are not suitable for dealing with the EM. Accordingly, it is necessary to optimize the properties of the EM in ways that would provide more scientific and environmentally friendly solutions.
Considering the extensive distribution of the EM in the geotechnical field, most scholars have used EM in combination with simple sieving to make it become an aggregate of concrete materials, which has been used to replace part of the amount of natural sand and improve the performance of concrete [8, 9]. However, few scholars have studied the clay minerals in the EM. The EM in subtropical areas is the product of a combination of climate, rainfall, and temperature factors. The humid environment accelerated the weathering process [10, 11]. This process not only decomposes solid rock and soil but also increases the dissolution and leaching of carbonates, resulting in the formation of clay minerals such as kaolinite, halloysite, and illite [12]. Therefore, the EM can be considered to pre-treated by mechanical and heat treatment mechanisms that activated the chemical activity of clay minerals, making the EM a natural precursor for geopolymers. The process of geopolymerization typically includes the dissolution of silicate and aluminate compounds in a highly alkaline environment, leading to the formation of geopolymer [13]. Accordingly, geopolymerization technology offers the potential to enhance the value of the EM, since the activated EM capable of reacting with the alkaline solutions to produce high-performance geopolymer [14]. Geopolymers are considered as a sustainable building material due to the abundance of raw materials that produce superior durability, mechanical and thermal properties.
Many studies have shown that the geopolymers prepared by clay minerals have excellent mechanical and microscopic properties [15]. These properties of the geopolymers are influenced by a variety of factors, such as the properties of raw materials, synthesis parameters (the type, proportion, concentration of alkaline activators, liquid-solid ratio), and curing conditions, etc [16–18]. As the EM was rich in clay minerals, the EM can be used to prepared geopolymers, which were also affected by these factors. The properties of the raw materials are critical and directly related to the properties of the geopolymers. In addition, the synthesis parameters (proportion of the alkaline activator and the liquid-solid ratio) have also been shown to be key factors affecting the geopolymer, which are the focus of this study.
Based on the study by Duxson et al. (2007) [19], the dissolution of aluminate and silicate minerals as well as the ion type balance, are crucial for alkaline activation materials. The mixture of NaOH solution and Na2SiO3 solution is a commonly used alkaline activator in the preparation of the geopolymers, as it can effectively dissolve aluminates and silicate minerals [20, 21]. When exploring the proportions and concentration levels of the alkaline activator, the molar ratio of SiO2/Na2O emerges as the most critical factor. Gao et al. (2014) [22] found that when the SiO2/Na2O molar ratio was 1.50, the metakaolin-based geopolymer exhibited the largest compressive strength, and the densest microstructure with fewer unreacted particles. Ma et al. (2012) [23] demonstrated that the increase in the Na2O content can promote geopolymerization, whereas an increase in SiO2 content can enhance the microstructure of the geopolymers. In addition, water serves not only as the medium for dissolving aluminosilicate precursors and alkaline activators, but also supports the transformation of various ions and the polycondensation of Al and Si ions in geopolymerization. Lizcano et al. (2012) [24] demonstrated that liquid-solid ratio was a major factor affecting the density and porosity of the metakaolin-based geopolymer. These findings highlight the necessity for further research to determine the optimal SiO2/Na2O ratio of alkaline activator and liquid-solid ratio design for manufacturing the geopolymers with excellent performance.
From a sustainability perspective, in the production and design of the geopolymers, it is essential not only to consider various properties but also to incorporate environmental factors into considerations. Faced with the contradiction between economic development and ecological carrying capacity, especially in the construction industry and geotechnical engineering, adopting scientific methods to assess environmental impacts and adhering to Life Cycle Assessment (LCA) standards has become a necessary way to achieve emission reduction goals and transition to a resource-efficient society [25]. LCA is used to measure environmental impacts through various metrics, offering researchers an additional perspective for assessing the environmental analysis of preparing geopolymers. LCA has been widely applied to the environmental impacts of the geopolymers to confirm advantages over conventional concrete [26]. Critical to the evaluation of the LCA analysis is the selection of an appropriate mix design [27]. For the geopolymers, the use of the alkaline solutions is an important environmental consideration, and evaluating alkaline levels with LCA can provide effective environmental management strategies. However, the majority of these studies have focused on the fly ash-based or slag-based geopolymers [28–30], and relatively few LCA assessments of the EM-based geopolymers. This gap will limit the applications and development of more sustainable waste management strategies for the EM.
In recent years, the geopolymers have been used in geotechnical engineering fields, such as durable materials, infrastructure construction related to foundation and slope engineering [31], and building materials such as replacing cement [32]. The growth in population and urbanization has led to a significant surge in concrete demand [33]. However, as ordinary Portland cement (OPC) is a primary binder in concrete, the production of concrete is associated with significant energy consumption and dust generation, contributing considerably to carbon dioxide (CO2) emissions. [33, 34]. Globally, the cement industry accounts for approximately 10% of total CO2 emissions [35]. With the global drive to reduce carbon emissions, the geopolymers have received increasing attention as a suitable alternative to OPC due to their reduced environmental impact [36, 37]. In particular, the EM as raw materials for the geopolymers makes effective use of these wastes and reduces the environmental burden of waste disposal. The EM-based geopolymers show great potential as building materials, providing a sustainable and low-carbon solution for the building materials industry and geotechnical engineering.
In summary, in the field of geotechnical engineering, the landfill disposal for the EM in the subtropical region must be considered an inappropriate and wasteful of use construction resources. By combining the pre-treated EM and the alkaline solutions to prepare the EM-based geopolymers, it is possible to significantly enhance the utilization efficiency and value of the EM. The properties of the geopolymers are affected by the synthetic parameters, especially the proportion of the alkaline activators and liquid-solid ratio. Although the alkaline solutions used in the geopolymers have less impact on the environment than the traditional cement production process, its production and use process still inevitably causes a certain burden on the environment. Therefore, it is important to use LCA to comprehensively evaluate the environmental impact of the EM-based geopolymers. To develop the geopolymers with better performance and promote their application in geotechnical engineering, the optimal synthesis parameters and the LCA analysis of the alkaline-activated EM-based geopolymers need to be further studied.
Accordingly, in this study, clay minerals-rich EM was obtained through pretreatment. Subsequently, the EM was reacted with the alkaline solutions to prepare the EM-based geopolymers. The effects of different synthesis parameters (SiO2/Na2O ratio and liquid-solid ratio) on the development of compressive strength and microstructure in the EM-based geopolymer were investigated. A variety of characterization methods were employed to study the EM-based geopolymers, including X-ray diffraction (XRD), Fourier-transform infrared (FTIR) spectroscopy, scanning electron microscopy (SEM), mercury intrusion porosimetry (MIP), and thermogravimetric (TG) analysis. Furthermore, the environmental impact of the EM-based geopolymers and conventional concrete was analyzed and compared in terms of global warming (CO2 emissions) and acidification (SO2 emissions) through LCA. This study provides better insight into the properties and environmental effects of the EM-based geopolymers in the geotechnical engineering field.