Development of Geopolymer Composites Incorporating Eggshell and Fly Ash as Sustainable Construction Materials

Tan, Zhi Pin (2025) Development of Geopolymer Composites Incorporating Eggshell and Fly Ash as Sustainable Construction Materials. Final Year Project (Diploma), Tunku Abdul Rahman University of Management and Technology.

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Abstract

The construction industry produces a large amount of carbon dioxide (CO₂), mainly from the use of Ordinary Portland Cement (OPC). Because of this, many researchers are now looking for greener and more sustainable building materials. This project investigates the use of fly ash, an industrial by-product, and eggshell powder, a calcium-rich food waste, in the production of geopolymers aimed at reducing both environmental pollution and waste generation. In this study, fly ash was used as the main precursor material to react with alkaline solutions (sodium hydroxide and sodium silicate) to form the geopolymer. Eggshell powder was added in different amounts (0%, 10%, 20%, and 30%) to see how it affects the properties of the geopolymer. The samples were first sealed and cured at room temperature for 24 hours, then heated in an oven at 60 °C for another 24 hours, and finally kept at room temperature for either 7 or 28 days. Several tests were done, including compressive test, bulk density measurement, and Functional Group Identification (FTIR) analysis. The results revealed that incorporating 30% eggshell powder yielded the highest compressive strength after 28 days, reaching 125.74 kPa. In contrast, adding 10% to 20% eggshell powder led to reduced workability and lower strength. FTIR analysis indicated changes in chemical bonding, with the formation of new C–A–S–H gels in mixes containing eggshell powder. In conclusion, adding eggshell powder (up to 30%) can improve the strength of fly ash-based geopolymers and help turn waste into useful building materials. This supports the idea of using waste in construction to protect the environment and reduce cement use.