Abstract
Phosphogypsum (PG) is the main by-product of wet-process phosphoric acid production. Its annual global production reaches about 200 million tons, yet its utilization rate remains low. Consequently, long-term stockpiling of large PG volumes poses immense pressure to the ecological environment. To mitigate negative environmental impacts, the utilization of PG is imperative. Despite progress in PG utilization and 3D-printing technology, there is still a significant lack of understanding about the synergistic activation mechanisms in multi-solid-waste systems. In particular, the composition design, microstructure evolution, and structure-property relationships of 3D-printed PG-based composites are not well-studied, which limits their high-value engineering applications. Three-dimensional-printed phosphogypsum concrete (3DPPGC) is proposed here, promoting PG resource utilization by leveraging the expanding applications of 3D-printed concrete (3DPC). However, the strength of 3DPPGC needs to be enhanced to meet engineering requirements. This study designed the mix proportion of 3DPPGC and fabricated the corresponding test specimens. The optimal Cement Replacement Ratio (CRR) was determined through experimental testing, and the mechanism behind the strength enhancement of the 3DPPGC was elucidated. The results indicated that the 3DPPGC's mechanical properties peaked at the 70% CRR. Compared with cast specimens, 3DPPGC exhibited a 1.52% increase in 28-day flexural strength in the y-direction, reaching 4.69 MPa. The early-age compressive strength, flexural strength, and later-age compressive strength of 3DPPGC were significantly enhanced when PG, blast-furnace slag (BS), fly ash (FA), and silica fume (SF) were used to partially replace cement. This study provides a theoretical and experimental basis for the large-scale, high-value application of PG in intelligent construction.