Despite the rapid development of 3D printing technology for cement composites, there are still a number of unsolved issues related to extrusion printing. One of them is proper mix design that allows for meeting criteria related to the printing of cementitious materials, such as pumpability, buildability, consistency on the materials, flowability and workability, simultaneously incorporating sustainable development ideas. In the case of mixes for 3D printing, the modification of the composition which increases the overall performance does not always go hand in hand with the reduction of negative environmental impact. The article presents the results of tests of eight mixtures modified with reactive and inert mineral additives designed for 3D printing. The mixes were evaluated in terms of their rheological and mechanical properties as well as environmental impact. Initial test results were verified by printing hollow columns up until collapse. Later, the differences between the compressive strength of standard samples and printed columns were determined. In order to summarize the results, a multi-faceted analysis of the properties of the mixes was carried out, introducing assessment indicators for its individual parameters. The article proves that appropriate material modification of mixes for 3D printing can significantly reduce the negative impact on the environment without hindering required 3D printing properties.

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.

The article presents overview of additive manufacturing for concrete structures. Study focuses on specific tests used to determine suitability of high performance mixes for 3D printing. The tests include determination of compressive strength and evaluation of printing speed, extrudability and overall surface quality. Tests were performed on a High-Performance Concrete mix with fine natural aggregate up to 2 mm. Mineral additives such as silica fume and fly ash, and superplasticizer were added to obtain proper consistency. The tests were performed using specially designed site consisting of Cartesian robot and pumping module. The design of printed paths were tailored for specific tests. The evaluation of pump performance was made by measuring pumped mix volume in time. The determination of correct pumping speed was made based on the visual quality of the printed layers. Study determines also the ability to print multilayered structures and printability window of proposed mix.

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.