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<p>The development of sustainable and high-performance construction materials necessitates innovative approaches that simultaneously enhance mechanical properties and durability. In this study, a chemically engineered dual-network alkali-activated geopolymer system was developed by integrating phosphate-induced crosslinking and carbonate mineralization, combined with hybrid micro–nano reinforcement. The objective was to establish a chemo-mechanical design framework capable of controlling gel chemistry, pore structure, and fracture behavior. Geopolymer composites were synthesized using fly ash and ground granulated blast furnace slag with controlled incorporation of phosphate and carbonate phases, along with fiber and nano-scale additives. A comprehensive experimental program was conducted to evaluate mechanical performance, durability under aggressive exposures, microstructural evolution, and transport properties. Additionally, an artificial neural network (ANN) model was developed to predict performance and enable multi-objective optimization. The dual-network system demonstrated significant performance enhancement, with compressive strength increasing from ~ 35&#xa0;MPa to ~ 50&#xa0;MPa and fracture energy doubling from ~ 80&#xa0;N/m to ~ 160&#xa0;N/m, indicating improved toughness and quasi-ductile behavior. Durability performance showed substantial improvement, with chloride permeability reduced by ~ 70% (from ~ 3400&#xa0;C to ~ 1000&#xa0;C), carbonation depth reduced by ~ 68%, and enhanced resistance to sulfate and freeze–thaw degradation. Microstructural analysis confirmed pore refinement from ~ 90–100&#xa0;nm to ~ 30–40&#xa0;nm due to combined gel crosslinking and carbonate precipitation. The ANN model achieved high prediction accuracy (R² up to 0.972) and identified nano-additives, carbonate content, and fiber reinforcement as dominant factors. The proposed system offers a CO₂ reduction of ~ 60–80% compared to conventional cement, demonstrating strong potential for sustainable structural applications.</p>

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Chemically Engineered Dual-Network Carbonate-Phosphate Alkali-Activated Geopolymer Reinforced with Hybrid Micro-Nano Reinforcements for High-Durability Structural Concrete

  • 期刊论文

  • 发表日期：

    2026年7月6日

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  • Moulya H V

摘要

The development of sustainable and high-performance construction materials necessitates innovative approaches that simultaneously enhance mechanical properties and durability. In this study, a chemically engineered dual-network alkali-activated geopolymer system was developed by integrating phosphate-induced crosslinking and carbonate mineralization, combined with hybrid micro–nano reinforcement. The objective was to establish a chemo-mechanical design framework capable of controlling gel chemistry, pore structure, and fracture behavior. Geopolymer composites were synthesized using fly ash and ground granulated blast furnace slag with controlled incorporation of phosphate and carbonate phases, along with fiber and nano-scale additives. A comprehensive experimental program was conducted to evaluate mechanical performance, durability under aggressive exposures, microstructural evolution, and transport properties. Additionally, an artificial neural network (ANN) model was developed to predict performance and enable multi-objective optimization. The dual-network system demonstrated significant performance enhancement, with compressive strength increasing from ~ 35 MPa to ~ 50 MPa and fracture energy doubling from ~ 80 N/m to ~ 160 N/m, indicating improved toughness and quasi-ductile behavior. Durability performance showed substantial improvement, with chloride permeability reduced by ~ 70% (from ~ 3400 C to ~ 1000 C), carbonation depth reduced by ~ 68%, and enhanced resistance to sulfate and freeze–thaw degradation. Microstructural analysis confirmed pore refinement from ~ 90–100 nm to ~ 30–40 nm due to combined gel crosslinking and carbonate precipitation. The ANN model achieved high prediction accuracy (R² up to 0.972) and identified nano-additives, carbonate content, and fiber reinforcement as dominant factors. The proposed system offers a CO₂ reduction of ~ 60–80% compared to conventional cement, demonstrating strong potential for sustainable structural applications.