Study on Temperature-Dependent Properties and Fire Resistance of Metakaolin-Based Geopolymer Foams

This paper presents temperature-dependent properties and fire resistance of geopolymer foams made of ground basalt fibers, aluminum foaming agents, and potassium-activated metakaolin-based geopolymers. Temperature-dependent properties of basalt-reinforced geopolymer foams (BGFs) were investigated by a series of measurements, including apparent density, water absorption, mass loss, drying shrinkage, compressive and flexural strengths, XRD, and SEM. Results showed that the apparent density and drying shrinkage of the BGFs increase with increasing the treated temperature from 400 to 1200 °C. Below 600 °C the mass loss is enhanced while the water absorption is reduced and they both vary slightly between 600 and 1000 °C. Above 1000 °C the mass loss is decreased rapidly, whereas the water absorption is increased. The compressive and flexural strengths of the BGFs with high fiber content are improved significantly at temperatures over 600 °C and achieved the maximum at 1200 °C. The BGF with high fiber loading at 1200 °C exhibited a substantial increase in compressive strength by 108% and flexural strength by 116% compared to that at room temperature. The enhancement in the BGF strengths at high temperatures is attributed to the development of crystalline phases and structural densification. Therefore, the BGFs with high fiber loading have extraordinary mechanical stability at high temperatures. The fire resistance of wood and steel plates has been considerably improved after coating a BGF layer on their surface. The coated BGF remained its structural integrity without any considerable macroscopic damage after fire resistance test. The longest fire-resistant times for the wood and steel plates were 99 and 134 min, respectively. In general, the BGFs with excellent fire resistance have great potential for fire protection applications.