The high liquid content of cast geopolymer not only limits its strength development and durability but also leads to high energy consumption and carbon dioxide (CO2) emissions. Thus, a study of the cast and pressed geopolymer was performed. The geopolymers were cured for 1, 7 and 28 d before testing and characterizations. With the incorporation of pressure compaction, higher bulk density (2158–2227 kg/m3) was recorded for pressed geopolymer in comparison to cast geopolymer (1842–1854 kg/m3). The dense matrix in pressed geopolymer improved the inter-particle contact, increasing the 28 d degree of reaction to 39.7%, higher than that of cast geopolymer (33.0%). This feature was proved by SEM micrographs wherein the pressed geopolymer was well-compacted and denser in microstructure, with less unreacted/partially reacted fly ash and pores. The compressive and flexural strengths of pressed geopolymer reached 114.2 and 29.9 MPa after 28 d, higher than that of cast geopolymer (60.0 and 6.2 MPa, respectively). The strength reduction of pressed geopolymer (31.7%) after the accelerated efflorescence test was lower than that of cast geopolymer (60.2%). The ecological analysis inferred that pressed geopolymer was ecologically superior to the casting method in terms of embodied energy (EE) and embodied carbon dioxide emission (ECO2), in which 50% and 59% of reductions are acquired. Besides, the embodied carbon index (ECI) of pressed geopolymer was about 21% of cast geopolymer.
