The project builds upon the preliminary results of the Ecosister initiative, which investigated geopolymer binders activated with both solid and liquid activators. Since liquid-activated binders demonstrated superior mechanical performance, the present proposal focuses on their structural application through the development of geopolymer concrete (GPC) for precast segments intended for the rehabilitation of existing reinforced concrete or masonry tunnels. The project starts from a TRL3 binder and aims to achieve TRL7 through the production of a full-scale structural prototype.

The main objectives are: to identify a high-performance geopolymer binder (mechanical, thermal, and durability properties); to define a mix design for fibre-reinforced GPC suitable for industrial production, ensuring adequate workability and high mechanical and fire resistance; to develop a “design by testing” procedure for precast elements; and to manufacture a full-scale demonstrator segment verified under ultimate and serviceability limit states.

The development plan includes binder selection and characterization, mix design optimization, mechanical and physico-chemical testing in comparison with OPC, Life Cycle Assessment (LCA) and Life Cycle Cost (LCC) analyses, full-scale structural validation, and industrial prototype production.

Expected impacts include reduced CO₂ emissions through slag-based GPC, enhanced infrastructure resilience due to improved fire resistance, new market opportunities for the precast industry, and progress toward the standardization of geopolymer concrete in Italy.