3D printable earth-based alkali activated ink: Effect of alkali concentration and binder-to-aggregate ratio

This research attempts to investigate the effect of activator concentration (4 mol/L (M) and 8M) and binder-to-aggregate (B:A) ratio (ranging from 1:1 to 1:3 by weight) on extrudability and buildability of 3D printable natural earth-based alkali-activated materials (EAAM). It is found that natural clay in soil, used to replace 25 % of M-sand, imparts higher thixotropy, evident from 90 to 100 % recovery in viscosity compared to 65–80 % for corresponding control (containing only M-sand and no soil). Presence of clay increases the dynamic yield stress than control but reduces the plastic viscosity by 80 – 90 % in EAAM compared to corresponding control where interlocking between sand particles resists smooth extrusion of the material. EAAMs made with 8M NaOH have higher flow retention and maintain 95–100 % recovery in viscosity for longer duration than 4M EAAM. This contributes to superior extrusion quality of 8M EAAM than 4M EAAM. The findings suggest that binder content can be reduced as concentration of NaOH is increased from 4M to 8M. This is evident from lower layer deformation (0.09 % of original height) under self-weight and higher 3D printed buildable height of at least 457 mm in 8M EAAM with B:A of 1:2 compared to a maximum of 375 mm for 4M EAAM at higher B:A of 1:1. Ratios of wet compressive strength to dry compressive strength vary between 0.92 and 1.09 in 8M EAAM compared to 0.79 – 0.85 for 4M EAAM at 28-day age, suggesting lower sensitivity to moisture due to improved clay stabilization. Based on the strength and moisture sensitivity, the developed material can serve as a low-carbon and durable alternative to Portland cement in the construction of masonry elements in buildings, including cavity walls, panels, flooring tiles and façade members. © 2024 Elsevier Ltd