Effect of Process Parameters on the Physical and Mechanical Properties of Cornstarch-Based Construction Materials

Concrete is used globally due to its useful mechanical and durability properties. However, concrete requires a massive amount of cement, which is the second-largest source of carbon emission (5–7% of global CO2 emissions) due to its high energy consumption. The gelatinization effect of corn starch as a binder has been explored in the place of cement in concrete. However, there is a need to optimize the various processing conditions to enhance the material strength of the corn starch-based material known as CoRncrete. Two experiments were conducted to optimize the ratio of sand, starch, water, curing temperatures, and time. The compressive and tensile strength of the CoRncrete samples were analyzed. The results showed that the optimum processing conditions having a sand grain size of 0.250–0.425 mm, a mixture ratio of starch, water, and sand 1:1:5, and curing temperature and time of 110 °C and 24 h can yield a maximum compressive strength up to 18.9 MPa. Statistical analysis revealed that the size of sand grains and curing temperatures had the most significant impact on the material’s strength. Microstructural analysis, employing scanning electron microscopy (SEM) and micro-computed tomography (microCT), unveiled numerous internal pores and cracks within the hardened cubic blocks, which significantly decreased the strength. Consequently, future investigations should concentrate on reducing internal pore spaces and cracks to enhance the durability of CoRncrete.