Development of high-CaO fly ash-based alkali-activated mortar for 3D printing technology
Source abstract
Abstract
A one-part alkali-activated mortar was developed for 3D printing technology (3DPT). High-CaO fly ash (FA) served as a binder, while sodium metasilicate (SM) was added as the alkali activator at dosages between 3.0% and 9.0% by weight of the binder. Moreover, bottom ash (BA) was used to replace the fine aggregate at substitution rates of 50% and 100% by volume of fine aggregate, serving as an internal curing material and reducing mortar density. Micro polypropylene fibers (PPF) with lengths of 6 and 9 mm were also added to the mixture at a rate of 0.2% by volume to improve the buildability of 3D printing mortar (3DPM). The flowability of the mortar was maintained between 180 and 190 mm by varying the water-to-binder (W/B) ratio. The mortar’s fresh and hardened properties, mechanical properties, and microstructure were investigated. The results indicated that increasing the SM content required a lower W/B ratio to maintain the target flowability, which in turn shortened the setting times and enhanced the compressive strength of the mortar. Increasing the replacement level of fine aggregate with BA resulted in slightly shorter setting times, lower density, and reduced length change behavior. The 4.5SM mortar exhibited optimal 3DPM properties, resulting in superior buildability, shape stability, and filament consistency, while also achieving the highest 90-day compressive strength of 22.7 MPa. The addition of PPF significantly improved the buildability and interlayer bonding. The microstructural analysis revealed that the main reaction products in the paste were aluminosilicate hydrates (N, C-A-S-H) and calcium silicate hydrate (C-S-H), which contributed to improved mechanical performance. • High-CaO fly ash was served as binder to produce one-part alkali activated mortar for 3DPT. • Fresh and hardened properties and quality of printed sample of 3DPM were investigated. • SM at 4.5% was the most suitable for use as an alkali activator to produce 3DPM. • The addition of PPF in 3DPM significantly improved the buildability and stability.
Source: openalex_inverted_index · Quality: baseline
Research context
OpenAlex topics: Innovations in Concrete and Construction Materials · Concrete and Cement Materials Research · Innovative concrete reinforcement materials
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (63)
Show source-provided references
1. 3D-printable alkali-activated concretes for building applications: a critical review10.1016/j.conbuildmat.2021.126126 ↗
2. Three-dimensional laser printing of macro-scale glass objects at a micro-scale resolution10.3390/mi10090565 ↗
3. Overview of the development of 3D-printing concrete: A review10.3390/app11219822 ↗
4. Alkali activated materials applied in 3D printing construction: A review
5. A review of “3D concrete printing”: Materials and process characterization, economic considerations and environmental sustainability
6. Additive manufacturing as an enabling technology for digital construction: a perspective on Construction 4.010.1016/j.autcon.2019.03.011 ↗
7. Fresh and hardened properties of extrusion-based 3D-printed cementitious materials: a review10.3390/su12145628 ↗
8. A review of 3D printing low-carbon concrete with one-part geopolymer: engineering, environmental and economic feasibility
9. Large-scale 3D printing concrete technology: current status and future opportunities10.1016/j.cemconcomp.2021.104115 ↗
10. Logistic cost analysis for 3D printing construction projects using a multi-stage network-based approach10.1016/j.autcon.2023.104863 ↗
11. Use of high fineness of fly ash to improve properties of recycle aggregate concrete10.1061/(ASCE)MT.1943-5533.0000054 ↗
12. Physical, chemical, and geotechnical properties of coal fly ash: a global review
13. Application of fly ash to improve workability, heat generation, autogenous shrinkage, and cost-effectiveness of high strength concrete
14. Fresh properties and compressive strength of high calcium alkali activated fly ash mortar10.1016/j.jksues.2017.06.001 ↗
15. Development of high strength one-part geopolymer mortar using sodium metasilicate10.1016/j.conbuildmat.2019.117611 ↗
16. A consideration on the one-part mixing method of alkali-activated material: problems of sodium silicate solubility and quick setting10.1016/j.heliyon.2022.e08783 ↗
17. Mechanical and microstructural properties of high calcium fly ash one-part geopolymer cement made with granular activator10.1016/j.heliyon.2019.e02255 ↗
18. The mechanical properties and heat development behavior of high strength concrete containing high fineness coal bottom ash as a pozzolanic binder10.1016/j.conbuildmat.2020.119239 ↗
19. Influences of high-volume coal bottom ash as cement and fine aggregate replacements on strength and heat evolution of eco-friendly high-strength concrete
20. Effect of coal bottom ash as partial replacement of sand on properties of concrete10.1016/j.resconrec.2012.12.006 ↗
21. Effects of high-volume bottom ash on strength, shrinkage, and creep of high-strength recycled concrete aggregate10.1016/j.conbuildmat.2022.129233 ↗
22. Method for the enhancement of buildability and bending resistance of 3D printable tailing mortar
23. Improving printability of limestone-calcined clay-based cementitious materials by using viscosity-modifying admixture10.1016/j.cemconres.2020.106040 ↗
24. 3D printing of fibre cement-based materials: fresh and rheological performances
25. ASTM C618 · 2022
26. Influence of coal bottom ash as fine aggregate replacement on the mechanical properties of stone mastic asphalt10.3390/app15126826 ↗
27. The effect of different ratio bottom ash and fly ash geopolymer brick on mechanical properties for non-loading application
28. Modification effect of nanosilica and polypropylene fiber for extrusion-based 3D printing concrete: printability and mechanical anisotropy
29. Evaluation of fresh and mechanical properties and shrinkage of hydrophobic mortar containing microfiber for 3D printing technology
30. ASTM C1437 · 2020
31. Printability region for 3D concrete printing using slump and slump flow test10.1016/j.compositesb.2019.106968 ↗
32. ASTM C807 · 2021
33. ASTM C109, Standard test method for compressive strength of hydraulic cement mortars (using 2-in. or [50-mm] cube specimens), ASTM Inter. West Conshohocken, PA, 2020.
34. ASTM C157, Standard test method for length change of hardened hydraulic-cement mortar and concrete, ASTM Inter. West Conshohocken, PA, 2017.
35. Utilization of industrial by-products as binders and fine aggregates for one-part lightweight controlled low strength materials: Turning waste to value approach
36. Influence of bottom ash and polypropylene fibers on the physico-mechanical, durability and thermal performance of foam concrete: An experimental investigation10.1016/j.conbuildmat.2021.124887 ↗
37. Investigation of flow, compressive strength, shrinkage, and tensile properties of mortar with internal curing bottom ash
38. Development of high performance concrete using bottom ash as fine aggregate
39. The effect of polypropylene fiber with different length and dosage on the performance of alkali-activated slag mortar10.1016/j.conbuildmat.2021.124978 ↗
40. Influences of different types of fly ash and confinement on performances of expansive mortars and concretes10.1016/j.conbuildmat.2019.03.032 ↗
41. Development of 3D printable cementitious composites with the incorporation of polypropylene fibers10.3390/ma14164474 ↗
42. Effect of polypropylene fiber reinforcement on the consolidation swell and shrinkage behavior of lime blended expansive soil10.1080/14680629.2016.1272479 ↗
43. Shrinkage behavior of cementitious 3D printing materials: Effect of temperature and relative humidity10.1016/j.cemconcomp.2021.104238 ↗
44. Buildability and mechanical properties of 3D printed concrete10.3390/ma13214919 ↗
45. A roles of water film thickness and fibre factor in workability of polypropylene fibre reinforced mortar10.1016/j.cemconcomp.2018.07.014 ↗
46. The influence of polypropylene fiber on the working performance and mechanical anisotropy of 3D printing concrete10.3151/jact.19.1264 ↗
47. D. Hardjito, V.J.S. Wee, T.F. Ee, The use of fly ash and bottom ash in geopolymer mortar, Seminar Nasional Zeolite VII Conference, 17-18 October 2011, Hotel Majapahit, Surabaya.
48. An overview of recent advancements in fibre-reinforced 3D printing concrete10.3389/fmats.2023.1289340 ↗
49. Mechanical properties of 3D printed concrete in hot temperatures10.1016/j.conbuildmat.2020.120991 ↗
50. Comparative analysis of 3D printing of Portland cement mortars with hydroxypropyl methylcellulose and micro fibrillated cellulose as viscosity modifying agents10.1016/j.matdes.2024.113124 ↗
51. Enhancing the printing quality and mechanical properties of 3D-printed cement composites with date syrup-based graphene coated sand hybrid
52. Comparative study on morphology of ground sub-bituminus FBC fly ash geopolymeric material10.1016/j.apt.2015.04.013 ↗
53. An overview of the chemistry of alkali-activated cement-based binders10.1533/9781782422884.1.19 ↗
54. Zeolite formation in the presence of cement hydrates and albite10.1016/j.pce.2017.02.006 ↗
55. Effect of albite on shrinkage and carbonation resistance of alkali-activated slag10.1016/j.conbuildmat.2023.134141 ↗
56. Understanding the gel compatibility and thermal behavior of alkali activated Class F fly ash/ladle slag: The underlying role of Ca availability10.1016/j.cemconres.2023.107198 ↗
57. Characterization of the expansion due to the delayed ettringite formation at the cement paste-aggregate interface10.1016/j.conbuildmat.2021.122979 ↗
58. Acid resistance of calcium aluminate cement–fly ash F blends10.1680/jadcr.15.00139 ↗
59. Effect of SiO2 and Al2O3 on the setting time and hardening of high calcium fly ash-based geopolymer systems10.1007/s10853-012-6353-y ↗
60. Characterisation of reactive magnesia and sodium carbonate-activated fly ash/slag paste blends10.1016/j.conbuildmat.2015.06.015 ↗
61. One-part alkali-activated soil stabilization with sodium metasilicate: Mechanical-geochemical-mineralogical characterization
62. Strength behavior and autogenous shrinkage of alkali-activated mortar made from low-calcium fly ash and calcium carbide residue mixture10.1016/j.conbuildmat.2021.125438 ↗
63. Application of ultra high-performance mortar for producing high-performance pervious concrete with low carbon emissions and cost