Developments in the automation of construction processes, observable in recent years, is focused on speeding up the construction of buildings and structures. Additive manufacturing using concrete mixes are among the most promising technologies in this respect. 3D concrete printing allows the building up of structure by extruding a mix layer by layer. However, the mix initially has low capacity to transfer loads, which can be particularly troublesome in cases of external components that need to be placed on top such as precast lintels or floor beams. This article describes the application of additive manufacturing technology in the fabrication of a building wall model, in which the door opening was finished with automatic lintel installation. The research adjusts the wall design and printing process, accounting for the rheological and mechanical properties of the fresh concrete, as well as design requirements of Eurocode. The article demonstrates that the process can be planned precisely and how the growth of stress in fresh concrete can be simulated, against the strength level developed. The conclusions drawn from this research will be of use in designing larger civil structures. Furthermore, the adverse effects of concrete shrinkage on structures is also presented, together with appropriate methods of control.

This paper explores the new potential strategy of using fine recycled aggregates (fRA) derived from waste 3D printed concrete (3DPC) as a substitute for cement in additive manufacturing. This study hypothesizes that fRA can optimize mixture design, reduce cement content, and contribute to sustainable construction practices. Experimental programs were conducted to evaluate the fresh and hardened properties, printability window, and buildability of 3DPC mixes containing fRA. Mixes with replacement rates of cement with fRA by 10 vol%, 20 vol%, 30 vol%, 40 vol%, and 50 vol% were produced. A comprehensive experimental protocol consisting of rheological studies (static and dynamic yield stress), dynamic elastic modulus determination (first 24 h of hydration), flexural and compressive strengths (2 d and 28 d), and an open porosity test was performed. The obtained results were verified by printing tests. In addition, an economic and environmental life cycle assessment (LCA) of the mixes was performed. The results indicate that up to 50 vol% cement replacement with fRA is feasible, albeit with some technical drawbacks. While fRA incorporation enhances sustainability by reducing CO₂ emissions and material costs, it adversely affects the printability window, green strength, setting time, and mechanical properties, particularly in the initial curing stages. Therefore, with higher replacement rates (above 20 vol%), potential optimization efforts are needed to mitigate drawbacks such as reduced green strength and buildability. Notably, replacement rates of up to 20 vol% can be successfully used without compromising the overall material properties or altering the mixture design. The LCA analysis shows that reducing the cement content and increasing the fRA addition results in a significant reduction in mix cost (up to 24%) and a substantial decrease in equivalent CO₂ emissions (up to 48%). In conclusion, this study underscores the potential of fRA as a sustainable alternative to cement in 3D printed concrete.

The use of lightweight concrete (LWC) for structural and non-structural applications has attracted great interest in recent years. The main benefits include reduced deadload of structural elements and generally lower production and transportation costs. However, a decrease in concrete density often leads to a decrease in strength and durability. Typically, concretes are mostly modified with mineral additives such as silica fume or fly ash. Because of the recent developments in nanotechnology, research attention has turned to the possibility of improving concrete properties with nanomaterials, i.e., nano-SiO₂. However, there are still certain issues with the dosage and efficiency of nanomaterials. Therefore, in order to establish the current state of knowledge in this field, this review gathers most recent results about the performance of LWC modified with nanomaterials. The review is divided into sections about the influence of nanoparticles on the fresh properties of concrete and their influence on the mechanical and durability characteristics. The paper studies in depth the most common approach to nanomaterials in concrete technology and proposes areas for further development.

This study reports a potential approach for the valorization of glass waste (GW) that is mainly composed of amorphous silica to prepare lightweight foamed glass (FG). The preparation of FG was achieved by mixing sodium hydroxide with GW powder followed by sintering at a temperature of 800 °C. As-synthesized FG was characterized and applied as an effective adsorbent for the removal of hazardous organic water contaminants, in particular, methylene blue (MB) dye. FG exhibited porosity of 91%, bulk density of 0.65 g/cm³, compressive strength of 4 MPa, and thermal conductivity of 0.27 W/m·K. Theoretical treatment indicated that a monolayer model with one energy site was the best in fitting the removal of MB molecules. The number of MB molecules per active site (n) ranged from 2.20 to 1.70, suggesting vertical orientation and a multi-molecular adsorption mechanism. The density of FG receptor sites (D_M) increased with the temperature, and this parameter played a vital role in the adsorption process. The adsorption capacity (Q_sat) increased from 255.11 to 305.58 mg/g, which signifies endothermic interactions. MB adsorption on FG was controlled by physical forces such as electrostatic interactions (i.e., the adsorption energies were <20 kJ/mol). The results of this study prove the feasibility of glass waste as an effective and low-cost adsorbent for water remediation.

Few studies have focused on determining the Young’s modulus of 3D printed structures. This study presents the results of experimental investigations of Young’s modulus of a 3D printed mortar. Specimens were prepared in four different ways to investigate possible application of different methods for 3D printed structures. Study determines the influence of the number of layers on mechanical properties of printed samples. Results have shown a strong statistical correlation between the number of layers and value of Young’s modulus. The compressive strength and Young’s modulus reduction compared to standard cylindrical sample were up to 43.1% and 19.8%, respectively. Results of the study shed light on the differences between the current standard specimen used for determination of Young’s modulus and the specimen prepared by 3D printing. The community should discuss the problem of standardization of test methods in view of visible differences between different types of specimens.