Porosity control of cold consolidated geomaterial foam: Temperature effect

Porous K-geopolymers with mutli-scale porosity were synthetized, based on the production of molecular hydrogen due to the oxidation of free silicon associated with polycondensation reactions. The various drying steps at low temperatures influencing the foams morphology were evaluated in function of parameters like mass effect, mold dimensions and drying cycles. The results obtained evidenced the possibility to perform reproducible foams with a control of their porosity. These foams are in agreement with the environmental demand with their recycling properties and their low cost of production due to the cheap materials used and the low temperature of synthesis. Some other advantages like their fire resistance, acid/base resistance, their good mechanical properties and their good thermal conductivity is a good point for future applications. As an example a homogeneous foam with a pore size of 1.5 mm at 50 °C (9 days for an achieved drying but consolidated before) can be prepared. Moreover the porosity can be controlled with various temperature cycles decreasing the time of synthesis. From the cycles tested (70–55 °C and 70–23 °C), some homogeneous samples were obtained with pores sizes varying from 0.5 to 1.5 mm. Then the work was extended to larger surfaces exchange, what evidences the importance of drying and mass effects upon the porosity as well as the mechanical properties of the mold used during synthesis.