This paper investigates the physico-mechanical and acoustic properties of fly ash geopolymers via casting and pressing methods. The existing research lacks comprehensive insight into the relationship between variations in geopolymer density and their impacts on both physico-mechanical properties and sound insulation and absorption capabilities. Geopolymers, as sustainable construction materials, are pivotal in mitigating noise and providing structural strength. To surpass these limitations and achieve either higher or lower densities in geopolymers, alternative approaches are necessary. Casting (non-foamed and foamed with 1.0, 2.0 and 3.0 foam-to-geopolymer paste ratio) and pressing methods were employed to produce a range of geopolymer densities between 1400 kg/m3 – 2200 kg/m3. The pressing method produced a highly dense geopolymer with an excellent compressive strength of 116 MPa. While the lightest geopolymer produced by adding a foaming agent had a compressive strength of 13 MPa. Good sound transmission loss (66.1 dB) was achieved by highly dense pressed geopolymers. Highly porous geopolymers achieved an excellent sound absorption coefficient of 0.79. The density variation and preparation methods greatly affected the pore size and distribution which subsequently affected the acoustical properties of the geopolymers. Manipulating the density and porosity of the geopolymers is essential for creating spaces with optimal acoustics to meet building codes and noise control regulations.
