Green Protective Geopolymer Coatings: Interface Characterization, Modification and Life-Cycle Analysis

In the interest of solving the resource and environmental problems of the construction industry, low-carbon geopolymer coating ensures great durability and extends the service life of existing infrastructure. This paper presents a multidisciplinary assessment of the protective performance and environmental impacts of geopolymer coating. Various parameters, such as main substance, water-solid (W/S) ratio, activator type and curing time, were investigated for their effects on interface characterization in terms of contact angle, surface energy, mechanical properties and microstructure. These parameters had negligible effects on the amounts and types of hydrophilic functional groups of geopolymer surfaces. A combination of organic surface modifiers and geopolymer coatings was shown to ensure hydrophobic surface conditions and great durability. Silicon-based modifiers exhibited better wetting performance than capillary crystalline surfactants by eliminating hydroxyl groups and maintaining structural backbone Si-O-T (Si, Al) on geopolymers’ surfaces. Finally, life-cycle analysis was conducted to investigate the environmental performance. Geopolymer coating yielded substantially lower environmental impacts (50–80% lower in most impact categories) than ordinary Portland cement (OPC) coating. Silicon-based modifiers had negligible influence due to their minimal usage. Increasing the W/S ratio diluted the geopolymer coating and decreased the environmental impacts, and slag-based geopolymer coating achieved lower environmental impacts than FA-based and MK-based varietie.