A comprehensive review of materials, processing, and performance of nano-doped engineered geopolymer composites for construction applications

Abstract

This article provides a thorough evaluation of nano-doped engineered geopolymer composites, focusing on their materials, how they're made, and their performance in construction. Geopolymers are a promising low-carbon alternative to regular Portland cement (OPC). However, their natural brittleness limits their use in many structural applications. Fiber reinforcing promotes toughness, whereas nanomaterial integration presents new paths to optimize microstructure and improve mechanical and durability qualities. This review synthesizes research published between 2010 and 2025, pulling from key scientific databases. It focuses on studies that explore the combined use of fiber and nanomaterial reinforcement, improvements in processing methods, and the connections between structure and properties. The roles of key nanomaterials, such as nano-silica, carbon nanotubes, and nano-clays, are investigated. These materials are known for their ability to change the chemical properties of the matrix, improve the bond between fibers and the matrix, and help cracks spread. The effects of several processing methods, such as conventional casting and additive manufacturing, on the performance of composites are studied. The evaluation presents a rigorous study of mechanical behavior, impact resistance, fatigue performance, and durability under chemical, thermal, and environmental exposures. The discussion also covers the challenges of nanomaterial dispersion, scalability, standardization, cost, and environmental concerns, alongside new possibilities in hierarchical design, multifunctional self-sensing composites, and AI-assisted optimization. This study provides a thorough assessment of the current status and future potential of nano-engineered geopolymer composites, focusing on their possible use in creating sustainable and resilient infrastructure.

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