The Behavior of Industrial Wastes as a Replacement for Metakaolin Before Geopolymerization: A Comparative Study

Today, several conventional wastes (fly ash, ground granulated blast furnace slags, etc.) are used as valid precursors for geopolymer synthesis. However, there are several new wastes that can be studied to replace geopolymer precursors. This study investigates the behavior of four industrial wastes—suction dust (SW1), red mud (SW2), electro-filter dust (SW3), and extraction sludge (SW4)—as 20 wt.% substitutes for metakaolin in geopolymer synthesis. The objective is to assess how their incorporation before alkali activation affects the structural, thermal, mechanical, chemical, and antimicrobial properties of the resulting geopolymers, namely GPSW1–4. FT-IR analysis confirmed successful geopolymerization in all samples (the main Si-O-T band underwent redshift, confirming Al incorporation in geopolymer structures after alkaline activation), and stability tests revealed that none of the GPSW1–4 samples disintegrated under thermal or water stress. However, GPSW3 showed an increase in efflorescence phenomena after these tests. Moreover, compressive strength was reduced across all waste-containing geopolymers (from 22.0 MPa for GP to 12.6 MPa for GPSW4 and values lower than 8.1 MPa for GPSW1–3), while leaching tests showed that GPSW1 and GPSW4 released antimony (127.5 and 0.128 ppm, respectively) above the legal limits for landfill disposal (0.07 ppm). Thermal analysis indicated that waste composition influenced dehydration and decomposition behavior. The antimicrobial activity of waste-based geopolymers was observed against E. coli, while E. faecalis showed stronger resistance. Overall, considering leaching properties, SW2 and SW3 were properly entrapped in the GP structure, but showed lower mechanical properties. However, their antimicrobial activity could be useful for surface coating applications. Regarding GPSW1 and GPSW4, the former needs some treatment before incorporation, since Sb is not stable, while the latter, showing a good compressive strength, higher thermal stability, and leaching Sb value not far from the legal limit, could be used for the inner reinforcement of building materials.