Rapidly Synthesized Microwave-Sintered Geopolymer Foam Utilizing Granite Waste: A Sustainable Approach for High-Performance Construction Materials

This study presents a novel, rapidly synthesized geopolymer foam fabricated from granite industrial waste using microwave sintering, reducing the demolding time from 7 days to 3 min and the overall processing time to 24 h, while enhancing mechanical performance. Five sample compositions (G1–G5) were prepared with varying granite powder and alkaline solution ratios, cured in a microwave for 3 min, and sintered for an additional 3 min. X-ray fluorescence (XRF), compressive strength tests, water absorption, thermogravimetric analysis (TGA), differential thermal analysis (DTA), and Fourier transform infrared spectroscopy (FTIR) were used for thorough characterization. The compressive strength increased progressively from 13 MPa (G1) to 20 MPa (G5), the total porosity decreased from 33.33% to 18.58%, the water absorption reached a minimum of 2.02% (G5), and the bulk density rose from 1.143 to 1.49 g/cm³. XRF analysis confirmed Si/Al molar ratios of 6.5–11.4, indicating enhanced aluminosilicate network development. FTIR confirmed progressive geopolymerization, with integrated Si-O-T band areas increasing from 41,900 a.u. (G1) to 44,680 a.u. (G5). The microwave sintering approach consumed over 90% less active energy than conventional thermal curing, significantly reducing associated CO₂ emissions and thereby supporting SDG 7, SDG 12, and SDG 13. These results position granite-waste-derived geopolymer foam as a high-performance, energy-efficient alternative to conventional fired bricks and cement-based construction materials.