A building faces several challenges across its lifecycle stages. Challenges such as production inefficiency and inadequate waste management hinder advancement in the construction industry. Furthermore, the sector has emerged as one of the largest producers of waste in the world, which can lead to detrimental impacts on the economy and the environment. Conventional approaches are insufficient to eradicate these concerns. Thus, practitioners have sought to implement novel methods to ameliorate the construction process. In this regard, design for manufacturing and assembly (DfMA) and design for deconstruction (DfD) have gained prominence, as studies have elucidated the methods’ unprecedented potential to wholly transform the construction process and mitigate the unwanted impacts brought about by the industry. This study identified the applications and benefits of DfMA and DfD in construction, as well as recent developments and research gaps, through a literature review, using Scopus as the primary database and MATLAB for conducting data text analytics. The current body of knowledge necessitates a further assessment of the following research gaps: (1) development of standard construction-oriented DfMA guidelines; (2) corroboration of the developed DfMA tools through practical application; (3) integration of these holistic design approaches with emerging technologies, such as additive manufacturing and digital fabrication; (4) comparison of structures constructed using DfMA and DfD with structures built with conventional approaches; (5) comprehensive application of DfD guidelines to structural systems; (6) integration of DfMA and DfD; (7) execution of sustainability assessment studies to evaluate the impact of DfMA and DfD; and (8) identification of solutions to the barriers to DfMA and DfD uptake in construction.

Aluminosilicate minerals have become an important resource for an emerging sustainable material for construction known as geopolymer. Geopolymer, an alkali-activated material, is becoming an attractive alternative to Portland cement because of its lower carbon footprint and embodied energy. However, the synthesis process requires typically a two-part system for alkali activation wherein the solid geopolymer precursor is mixed with aqueous alkali solutions. These alkali activators are corrosive and may be difficult to handle in the field-scale application. In this study, a one-part geopolymer in which coal fly ash was mixed with solid alkali activators such as sodium hydroxide and sodium silicate to form a powdery cementitious binder was developed. This binder mixed with soil only requires water to form the soil-fly ash (SO-CFA) geopolymer cement, which can be used as stabilized soil for backfill/foundation. This geopolymer product was then evaluated for chemical stability by immersing the material with 5% by weight of sulfuric acid solution for 28 days. Indication suggests that the geopolymer exhibited high resistance against acid attack with an observed increase of unconfined compressive strength even when the immersion time in acidic solution was increased to 56 days. The mineralogical phase, microstructure, and morphology of the material were characterized by X-ray diffraction (XRD), Fourier transform infrared (FTIR) spectroscopy, and scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX), respectively. Results not only confirmed the formation of gypsum due to acid attack but also indicated the dissolution of anorthite and albite that may have caused the microstructure to be composed of sodium aluminosilicate hydrate (N–A–S–H) and calcium (alumino) silicate hydrate (C(–A)–S–H) with poly(ferro-sialate-siloxo) and poly(ferro-sialate-disiloxo) networks. A column leaching test with deionized water was also performed on the soil-fly ash geopolymer to study the leachability of metals in the material. Results showed that arsenic exhibits higher mobility in the geopolymer as compared to that of cadmium, chromium, and lead.

A novel approach one-part geopolymer was employed to investigate the feasibility of enhancing the strength of in-situ soil for possible structural fill application in the construction industry. Geopolymer precursors such as fly ash and volcanic ash were utilized in this study for soil stabilization. The traditional geopolymer synthesis uses soluble alkali activators unlike in the case of ordinary Portland cement where only water is added to start the hydration process. This kind of synthesis is an impediment to geopolymer soil stabilizer commercial viability. Hence, solid alkali activators such as sodium silicate (SS), sodium hydroxide (SH), and sodium aluminate (SA) were explored. The influence of amount of fly ash (15% and 25%), addition of volcanic ash (0% and 12.5%), and ratio of alkali activator SS:SH:SA (50:50:0, 33:33:33, 50:20:30) were investigated. Samples cured for 28 days were tested for unconfined compressive strength (UCS). To evaluate the durability, sample yielding highest UCS was subjected to sulfuric acid resistance test for 28 days. Analytical techniques such as X-ray fluorescence (XRF), X-ray diffraction (XRD), and scanning electron microscope/energy-dispersive X-ray spectroscopy (SEM/EDX) were performed to examine the elemental composition, mineralogical properties, and microstructure of the precursors and the geopolymer stabilized soil.