Structuration and yield strength characterization of hybrid alkali-activated cement composites (HACC) for ultra-rapid 3D construction printing

Abstract

This study investigates the critical time-dependent rheological properties, including structuration rate and yield stress, of hybrid alkali-activated cement composites (HACC). HACC, a blend of geopolymer and cement paste, is examined to evaluate its suitability for ultra-rapid 3D construction printing (3DCP), which refers to a material’s ability to attain rapid structuration and buildability within 5–10 min after mixing, essential for additive manufacturing of 3D structures. The investigation extends to the impact of filler materials like silica sand and PVA fibers on HACC’s rapid structuration. Vicat needle, fast- and slow-penetration resistance measurements indicate that setting time increases with decreasing the Silicon/Aluminum (S/A) molar ratio and the addition of silica sand. Conversely, the addition of fibers reduces setting time while enhancing yield strength. Specifically, HACC mixtures with 0.5% and 1% PVA fiber additions, alongside combined sand (30%, 40%) and fiber (0.5%) mixtures, demonstrate ultra-rapid setting behavior within 3–5 min. Notably, mixtures with 40% silica sand and 0.5% PVA fiber exhibit highest yield strength development, i.e., 14 MPa at 12 min. Remarkably, incorporating 1% fibers into the HACC mixture yields the highest 28-day compressive strength (∼80 MPa) and flexural strength (∼11 MPa). The synergistic interplay between geopolymer and cement facilitates rapid setting time and high early-age strength development in HACC mixtures. The varying effects of silica sand and PVA fiber on setting time and yield strength provide opportunities for designing suitable structuration profiles. These findings underscore the exceptional rapid setting, structuration, and mechanical properties of HACC, positioning it as a promising material for ultra-rapid 3D construction printing.