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University of Delaware junior Conner Nelms, a chemical and biomolecular engineering major, is exploring ways to make cement alternatives that offer improved strength while having fewer environmental impacts. This work is part of Nelms’ summer undergraduate research experience at UD.

Summer Research: Building a better brick: youtube.com/watch?v=wed3NLgVcFA

Building a better brick

Photos by Kathy F. Atkinson | Video by Sam Kmiec

UD undergraduate Conner Nelms is scaling up clay-based construction materials as a lower-carbon alternative to cement

Editor’s note: Every year, hundreds of undergraduates at the University of Delaware pursue research under the guidance of a faculty mentor, especially during the summer months. Such experiences provided by UD — a nationally recognized research university — can be life-changing, introducing young scholars to a new field, perhaps even the path to a future career, as they uncover new knowledge. These spotlights offer a glimpse into their world.

Modern cement relies heavily on limestone and energy-intensive processing, making it a major contributor to carbon emissions and water use. At the University of Delaware, researchers are scaling up a clay-based alternative to cement, advancing from small laboratory samples to brick forms.

Rising junior Conner Nelms, a chemical and biomolecular engineering major, is helping drive that scale-up effort this summer, using locally sourced clays to create cement-like materials known as geopolymers. He's working in the laboratory of Norman Wagner, Unidel Robert L. Pigford Chair in Chemical Engineering. The lab also explores geopolymers derived from lunar regolith, the layer of dust and broken rock that covers the moon’s surface, as part of broader research into how infrastructure such as habitats and landing pads might one day be built beyond Earth.

University of Delaware junior Conner Nelms, a chemical and biomolecular engineering major, is exploring ways to make cement alternatives with fewer environmental impacts, as part of his summer undergraduate research experience at UD.
University of Delaware junior Conner Nelms, a chemical and biomolecular engineering major, is exploring ways to make cement alternatives with fewer environmental impacts, as part of his summer undergraduate research experience at UD.

What inspired you to pursue your first research experience, and what is your project? 

Nelms: I like figuring out new things, and some friends who had already spent time doing research encouraged me to give it a try because they thought I'd enjoy it. They were right. I feel really engaged in the work. 

I’m working on scaling up geopolymer technology. The graduate student I work with recently defended their dissertation on lunar applications, and the lab is now expanding toward terrestrial applications to see how viable it is to use locally sourced geopolymers for construction.

We’re working with two types of clay from White Clay Creek State Park: a white clay and a red clay. It isn't traditional pottery clay. It's more like dense soil with rocks and organic material mixed in. My project focuses on scaling these materials into larger brick forms and testing how well they perform.

Undergraduate researcher Conner Nelms examines a clay brick that has undergone compression testing to evaluate its ability to carry a load.
Undergraduate researcher Conner Nelms examines a clay brick that has undergone compression testing to evaluate its ability to carry a load.

Why does this research interest you, and what broader impact could it have?

Nelms: The broader purpose is sustainability. For every ton of cement produced, about one ton of carbon dioxide is emitted into the atmosphere. Using geopolymer-derived materials instead has the potential to cut those emissions significantly, with literature suggesting reductions of 30% to 60% are possible. It also requires much less water than traditional cement production.

Even partial adoption could make a real difference. If more of the construction industry eventually shifts toward geopolymers, the environmental benefits could be significant. That’s what motivates me. I’ve always valued sustainability and conservancy, so it’s rewarding to work on a project aligned with those values.

Measuring the man-made geopolymer bricks before and after testing allows researchers to examine a material’s durability under pressure.
Measuring the man-made geopolymer bricks before and after testing allows researchers to examine a material’s durability under pressure.

What does your research look like day to day?

Nelms: Most of my work focuses on preparing and testing geopolymer samples made from clays rich in aluminum- and silicon-containing minerals. I mix raw materials, form small samples and cure them under controlled conditions to see how different processing choices affect the final material.

The red clay gets its color from iron oxide, which also interferes with the geopolymer reaction, so samples made with it are weaker and less suitable for construction. The white clay is showing more promising results. I'm casting one-centimeter cubes and testing different liquid-to-solid ratios to study how the reaction speed and other factors affect compressive strength. We're also evaluating different curing methods, including ambient and sealed curing, because water plays an essential role in the reaction. 

Eventually, we'll move from one-centimeter cubes to two-inch cubes, compare those samples with traditional sand-based mixes, and test everything for compressive strength. The goal is to understand how formulation and processing influence performance so we can eventually scale the material into larger, construction-relevant forms.

Undergraduate summer research enables students to make new connections and network across disciplines. For Connor Nelms, that includes meeting researchers in materials science and engineering that can provide guidance as he considers ways to scale up his research in the future.
Undergraduate summer research enables students to make new connections and network across disciplines. For Connor Nelms, that includes meeting researchers in materials science and engineering that can provide guidance as he considers ways to scale up his research in the future.

What has surprised you most about conducting research?

Nelms: I was surprised by how collaborative research is. I expected it to feel more independent or competitive, but it’s been very open and supportive. On my first day, I attended a dissertation defense, and shortly after that I saw another graduate student defend their work. There were dozens of people in the room, and it was clear how much collaboration and mentorship went into each project. Even day to day in the lab, people are very willing to help. You can ask almost anyone a question. There’s a real sense of shared problem solving.

What has been the biggest challenge you’ve faced in the lab?

Nelms: The biggest challenge has been figuring out the next steps as the project evolves. I've had to blaze my own trail a bit, which means figuring things out in real time and asking a lot of questions. Sometimes that leads to productive progress, and other times I realize I need to head back to the drawing board.

Forming the bricks starts by sifting, drying and pulverizing clay from Delaware’s White Clay Creek into a fine powder. Nelm’s then combines the fine powder with an activating solution to form a geopolymer solution that can be formed into bricks and cured for testing.
Forming the bricks starts by sifting, drying and pulverizing clay from Delaware’s White Clay Creek into a fine powder. Nelm’s then combines the fine powder with an activating solution to form a geopolymer solution that can be formed into bricks and cured for testing.

What are your goals for the rest of the summer and beyond?

Nelms: My main goal is to gain hands-on research experience and continue building consistency in experimental work. The lab is also developing a machine-learning model that predicts compressive strength based on a material’s composition. I'd like to help generate enough reliable data to support that modeling, since much of the process is still manual and time intensive. More broadly, I want to better understand how materials science research moves from an idea in the lab to something that can make a real-world sustainability impact.

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