Alkali-activated and geopolymer materials developed using innovative manufacturing techniques: A critical review

The manufacturing of geopolymers and alkali-activated materials for precast and cast in-situ construction applications could be achieved using suitable production techniques, such as one-part production, pre-setting pressure and hot pressing, two-stage concreting, and 3-dimensional printing. Adequate selection and tailoring of the manufacturing methodology are imperative for overcoming characteristic application problems of these materials and achieving eco-efficiency and superior engineering properties. With distinctive benefits including rapid solidification, lower cost, saving natural resources, less energy consumption, and reduced carbon footprint, alkali-activated and geopolymer composites have emerged as a strong contender for replacing conventional concrete in diverse construction applications. Critical analysis of the literature on innovative production methods indicates that the one-part production technique is promising for the eliminating design complexity of these mixtures. The pre-setting pressure and hot pressing applications would allow the achievement of superior physical and mechanical characteristics in a short period of time, especially for the precast industry. The workability and setting problems of alkali-activated materials could be overcome using the two-stage concreting methodology. To be used in 3D printing of alkali-activated and geopolymer materials, remarkable development is required in terms of rheological aspects. Accordingly, this paper surveys pertinent and recent literature and critically reviews the state-of-the-art of alternative production techniques of alkali-activated and geopolymeric materials, along with its use in recent applications, identifies pertinent knowledge gaps, and defines future research directions.

Automated summary

By utilizing different production techniques like single-part production, pre-setting pressure and hot pressing, two-stage concreting, and 3D printing, geopolymers and alkali-activated materials can be manufactured for construction applications to replace conventional concrete. It is essential to carefully select and tailor the manufacturing methodology to overcome application problems and achieve eco-efficiency and superior engineering properties. The distinctive benefits of these materials, including rapid solidification, cost savings, resource conservation, energy consumption reduction, and lower carbon footprint, make them strong contenders in various construction applications.