Engineering cement-free high-performance Martian concrete with enhanced in-situ utilization of soil simulant: Curing across −20 °C–40 °C and CO2-rich environments

Mars is increasingly considered for colonization by virtue of its Earth-like conditions and potential to harbor life. Responding to challenges of the Martian environment and the complexity of transporting resources from Earth, this study develops a novel geopolymer-based high-performance Martian concrete (HPMC) using Martian soil simulant. The optimal simulant addition, ranging from 30% to 70% of the total mass of the binders, was explored to optimize both the performance of HPMC and its cost-effectiveness. Additionally, the effects of temperature (-20 °C-40 °C) and atmospheric (ambient and carbonated) curing conditions, as well as steel fibre addition, were investigated on its long-term compressive and microstructural performance. Optimal results showed that HPMC with 50% regolith simulant achieved the best 7-day compressive strength (62.8 MPa) and the remarkable efficiency improvement, a result of ideal chemical ratios and effective geopolymerization reaction. Under various temperature conditions, sub-zero temperatures (-20 °C and 0 °C) diminished strength due to reduced aluminosilicate dissolution and gel formation. In contrast, specimens cured at 40 °C and 20 °C, respectively, showed superior early and long-term strengths, with the 40 °C potential for moisture loss related shrinkage cracking and reduced geopolymerization. Regarding the atmospheric environment, carbonation curing and steel fibre addition both improved the matrix compactness and compressive strength, with carbon-cured fibre-reinforced HPMC achieving 98.3 MPa after 60 days. However, long-term exposure to high levels of CO₂ eventually reduced the fibres' toughening effect and caused visible damages on steel fibres.