DEVELOPMENT OF ULTRA-HIGH PERFORMANCE GEOPOLYMER MORTAR FOR CONSTRUCTION 3D PRINTING

Abstract

The construction industry faces a pressing need for sustainable materials that offer superior mechanical properties, durability, and printability. This research addresses this need by developing an ultra-high-performance geopolymer mortar specifically tailored for construction 3D printing. The study systematically identifies and evaluates suitable materials for geopolymer mortar through an extensive literature review and material selection process. A design of experiments (DOE) approach is employed to vary key parameters in geopolymer mortar formulations, followed by rigorous experimental validation. The research methodology involves the preparation of three different geopolymer compositions (G1, G2, G3) and testing for setting time, compressive strength, flexural strength, and buildability. Buildability testing includes viscosity analysis, shape retention testing, and extrudability testing to evaluate suitability for 3D printing applications. The study also tests 3D printed geopolymers for compressive strength and conducts a comparative analysis of composition development. Main research results indicate that G2 consistently exhibits the highest compressive and flexural strength across all tested durations, with shorter setting times compared to G1 and G3. However, printed geopolymers demonstrate lower compressive strength compared to molded counterparts, with G2 showing relatively higher retention. Additionally, G2 displays more favorable viscosity characteristics and good extrudability, suggesting suitability for smoother extrusion and better layer formation during printing. The findings of this research have significant industrial implications, offering a sustainable alternative to conventional construction materials. The development of ultra-high-performance geopolymer mortar for 3D printing applications enables faster and more efficient construction processes while reducing material wastage and enhancing structural performance. This research contributes to advancements in sustainable construction practices, paving the way for a more environmentally friendly and economically viable future in the construction industry.