Sustainable Manufacturing of Building Materials Using Clay Minerals and Industrial Byproducts

Clay minerals have long been used as building materials due to their natural abundance, as seen in traditional mudbricks and Roman concrete. However, modern construction materials, particularly concrete, are major contributors to global CO₂ emissions due to the high-temperature processing required for their production. Geopolymers, which use strong bases such as sodium hydroxide to strengthen aluminosilicates instead of high-temperature processing, have been explored as a more sustainable alternative. However, the synthesis of alkaline activators remains energy-intensive, necessitating the search for alternative binders that can enhance the mechanical properties of clay-based materials. Among naturally abundant clay minerals, kaolinite and smectite are widely mined and utilized in various industrial applications. Kaolinite offers structural rigidity and has been commonly used in ceramics and papermaking, while smectite’s expandable interlayer allows for the intercalation of various molecules. In this study, we explore using a nature-derived biopolymer as a binder to improve the mechanical properties of clay-based composites. We hypothesize that the biopolymer can mediate particle interactions, fill pore spaces, and modify the overall particle arrangement to enhance material strength. Our results demonstrate that incorporating a biopolymer-based bindersignificantly reduces the need for alkaline activators while enabling the fabrication of bricks with compressive strengths comparable to commercial bricks. The strengthening mechanism was investigated using spectroscopic and microscopic techniques, confirming enhanced structural integrity. Additionally, the developed material exhibits CO₂ storage capability, with an applied surface treatment ensuring long-term stability. We fabricated full-sized bricks and artistic structures to validate scalability, highlighting the potential for construction and creative applications. This study presents a sustainable approach to low-carbon building materials, demonstrating the potential to reduce reliance on energy-intensive processes while serving as a carbon storage site. This work offers a promising pathway toward carbon-neutral and environmentally friendly construction materials by leveraging naturally abundant resources and bio-derived binders.