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Utilising recycled brick aggregate in cementitious mixtures can decrease the overdependency on limited natural resources and improve the sustainability of concrete. This paper presents a potential solution to lower the amount of waste being landfilled and increase the sustainability of 3D concrete printing technology by combining low-carbon ternary blended cement with recycled aggregates. Hence, the effect of incorporating two types of recycled brick aggregate - clay brick (CBA) and engineering brick (EBA) on the properties of 3D printable ternary blended cement were investigated. The natural aggregate in a pre-existing 3D printable blend was substituted by up to 50 wt.-% with two varieties of recycled brick aggregates available throughout Europe. The recycled brick aggregates underwent characterisation to determine their properties. The fresh property evaluation using the green strength test was used to assess the effect of aggregate replacements on the mixture's shape stability. The mechanical performance of mixtures containing CBA and EBA, both cast and 3D printable mixes, was evaluated and compared to that of the control sample. The results indicated that incorporating recycled brick aggregate enhances green strength and Young's modulus significantly. Mechanical strength performance showed significant enhancement when incorporating RBA, which reached up to 67% and 55% for both cast and 3D printing methods, respectively. The suitability of the developed mix formulations for 3D printing was assessed by printing cylindrical objects.

Waste carbon fibers as reinforcing elements in construction materials have recently gained increasing interest from researchers, providing outstanding strength performance and a lower environmental footprint compared to virgin fibers. Combination with cement-free binders, namely alkali-activated materials, is becoming increasingly important for sustainable development in the construction industry. This paper presents results relating to the potential use of waste carbon fibers in alkali-activated mortars. The waste carbon fiber fraction utilized in this research is difficult to integrate as reinforcement in ceramic–cementitious matrices due to its agglomerated form and chemical inertness. For this reason, a nanoceramic coating pretreatment based on nanoclay has been implemented to attempt improvements in terms of deagglomeration, dispersibility, and compatibility with alkali-activated materials. After chemical–physical and microstructural analysis on the nanoclay-plated fibers (including X-ray diffraction, IR spectroscopy, contact angle measurements, and electron microscopy) mortars were produced with four different dosages of treated and untreated waste fibers (0.25 wt.%, 0.5 wt.%, 0.75 wt.%, and 1 wt.%). Mechanical tests and fractographic investigations were then performed. The nanoclay coating interacts compatibly with the waste carbon fibers and increases their degree of hydrophilicity to improve their deagglomeration and dispersion. Compared to the samples incorporating as-received fillers, the addition of nanoclay-coated fibers improved the strength behavior of the mortars, recording a maximum increase in flexural strength of 19% for a fiber content of 0.25 wt.%. This formulation is the only one providing an improvement in mechanical behavior compared to unreinforced mortar. Indeed, as the fibrous reinforcement content increases, the effect of the nanoclay is attenuated by mitigating the improvement in mechanical performance.

This study explores the potential of waste brick and geo-cement aggregates as substitutes for natural sand in alkali-activated materials (AAMs) for mortar production. With a focus on achieving net-zero construction and mitigating environmental impact, the study replaces Portland Cement (OPC) and virgin aggregates with waste materials and by-products. The investigation evaluates the substitution of sand (up to 100 % by weight) in AAMs with waste brick aggregates (WBA) and waste geo-cement aggregates (WGA) obtained from demolished construction and research lab waste, respectively. The research methodology involves assessing mechanical, durability, and microstructure properties to assess the performance of the developed AAMs with waste aggregates. Notably, AAM composites containing waste brick and geo-cement aggregates surpass natural aggregate composites in terms of mechanical strength, water absorption, freeze-thaw resistance, acid ingress, and chloride attack. The 7-day 50 % waste brick mixture achieved a maximum compressive strength of 61 MPa, while a 70 % waste geo-cement mortar mixture attained a maximum flexural strength of 12 MPa. Combinations, whether comprising waste brick or geo-cement mortar aggregates, demonstrate compressive strengths well over 40 MPa, rendering them suitable for heavy load-bearing structures. The 50 % waste geo-cement mortar mixture stands out with the lowest water absorption rate of 6 % and the least compressive strength loss of 13 % after the freeze-thaw test, with reductions of 6 % and 18 %, respectively, compared to the control. Additionally, 100 % waste brick AAMs exhibit the lowest compressive strength loss after chloride and acid attack tests, with reductions of 13 % and 2.5 %, respectively. When compared to all other mixtures, the 50 % waste brick aggregates mortar mixture obtained the best overall performance. The composites developed in this study affirm their suitability for use in heavy-load structural components, showcasing favourable mechanical and durable properties. These findings underscore the need for additional exploration in this direction to advance sustainable construction practices.

One-part alkali-activated materials (AAMs) can preserve natural resources and lower embodied carbon of the built environment by accommodating various wastes, industrial by-products, and end-of-life materials in their composition. This study investigates the feasibility of using end-of-life bricks in two physical states, powder and aggregate, to partially replace fly ash precursor and natural aggregate in AAMs, respectively. The mechanical characteristics, microstructure, water absorption, freeze-thaw and fire resistance of the modified AAMs were evaluated. The effect of adding different ratios of nano graphite platelets was also investigated. Results showed that brick-based one-part AAMs can achieve mechanical properties, pore structure, water absorption and freeze-thaw resistance comparable to fly ash-based AAM while having 65% better fire resistivity. Incorporating bricks as aggregate resulted in a maximum improvement of 17% and 27% in the AAMs' compressive and flexural strength levels, respectively, and a general enhancement in the freeze-thaw resistance with showing no reduction in compressive strength after exposure to elevated temperature. Incorporating 0.1 wt% nano-graphite further enhanced flexural strength by 30%, decreased water absorption by 18% and improved freeze-thaw resistance compared to the mix without nano-graphite. Moreover, adding up to 0.5% nano-graphite enhanced the fire resistivity of the composite, allowing it to exhibit 19% better strength performance than before exposure.

This study investigates the printability of one-part brick powder-based alkali-activated materials (AAMs) containing end-of-life brick particles as aggregate. The novel formulation showcases promise for 3D printing of small to medium-sized building blocks, reminiscent of a Lego-type system, capitalising on the rapid setting time inherent to one-part AAMs. The effect of replacing up to 50% by weight of natural aggregate with brick aggregate on the fresh properties of brick powder-based alkali-activated materials, including slump measurements, flowability, setting time, open time and green strength were investigated. In addition, the flexural and compressive strength of the 3D printed mixtures were determined and compared to those of cast specimens. The buildability and microstructure were also examined. The results showed that incorporating high porous and rough brick aggregate to replace natural aggregate is beneficial in improving the mixtures’ slump, which is essential for retaining the shape of the printed layers. However, it decreased the flowability, setting time and open time when incorporating up to 50% brick aggregate. The green, flexural and compressive strengths were increased with increasing brick aggregate content up to 50% due to enhancing interlock between the binder and brick aggregate, and the better compaction because of the absorption properties of brick aggregate. The mechanical results revealed the better performance of 3D printed specimens than the cast specimens. Moreover, the incorporation of brick aggregate enhanced the buildability of the mixtures showcasing their potential in advancing 3D printing capabilities.

There is an increasing trend in research projects and case studies to demonstrate the potential of Additive Manufacturing (AM) with concrete, better known as 3D concrete printing. Like ordinary construction, the latest upgrades on this topic are strongly focused towards improving eco-sustainability in terms of low-carbon materials. Low-carbon binders’ alternative to Portland cement and the utilisation of selected waste materials in place to virgin aggregates has high potential in fulfilling the sustainable development goals. In this paper, an experimental study was performed by incorporating ground waste tire rubber aggregates of different size gradation (0–1 mm and 1–3 mm) and replacement levels (50 v/v% and 100 v/v%) in a “greener” alkali-activated mix designed for 3D printing applications. First, the experimental program involved the optimization of mix design rheology and printing parameters to successfully integrate rubber aggregates into the printable alkali-activated mixtures. Then, a comprehensive characterization, including static mechanical testing, dynamic thermo-mechanical analysis, thermal conductivity testing, and acoustic insulation measurements was conducted. Comparison with identical Portland-based rubberized formulations designed for AM revealed better mechanical isotropy, flexural strength, thermo-mechanical behaviour, heat insulation, and high-frequency acoustic insulation for alkali-activated composites. The influence of rubber aggregate size on the fresh and hardened state behaviour of the mixes was also studied and discussed. Keeping the losses in mechanical strength restrained, the rubberized composites designed in this study have demonstrated significant thermal and acoustic insulation properties that are desired for energy-saving applications in buildings. The research verified the practicability of using waste aggregates in low-carbon binders for sustainable lightweight and thermo-acoustically effective applications, establishing an attractive starting point to address future research on material optimization for practical purposes.

The main objective of this study is to develop 3D printed heavyweight concrete (3DPHWC) to produce elements with a dry density of up to 3500 kg/m3 by replacing natural aggregate (SA) with magnetite aggregate (MA) up to 100%. A comprehensive systematic study was conducted to thoroughly assess mixtures' mechanical properties, physical proficiency, fresh properties, and printing qualities. The inclusion of MA exhibited the desired fresh properties required for 3D printing and promising physical and mechanical properties. Evaluation of the mechanical properties of designed 3DPHWC indicates that replacing SA with MA increases both cast and printed samples' strengths. The 3D printed M100 sample achieved higher 28 days flexural and compressive strengths by 18 % and 20 %, respectively, compared to printed control mix (M0). Micro-CT study correspondingly demonstrated improvements in the composites' porosity, pore size, and pore morphologies. The linear attenuation coefficients (LACs) and half-value layer (HVLs) for slow neutron and gamma-ray were measured to assess radiation shielding characteristics. A significant performance improvement was obtained for slow neutrons by introducing the magnetite aggregate. Unlike slow neutrons, no significant difference was observed between cast and printed samples against γ-rays. Moreover, the effect of porosity on the shielding performance was discussed.

3D printing is a developing technology that has the ability to use different materials to produce concrete elements with complex shapes. The utilization of geopolymers or alkali-activated materials (AAMs) in 3D printing is receiving significant interest due to the environmental benefits of replacing ordinary Portland cement (OPC). The use of solid activators to produce a one-part geopolymer can help the broader use of geopolymers at large scales, as the corrosive, viscous, and hazardous liquid activators used in two-part geopolymers do not present a feasible large-scale solution for this technology. This paper reviews the 3D printable one-part geopolymers, their compositions, and the effect of different precursor compositions, activator content, and different admixtures on the fresh and hardened properties of the mixtures. The environmental impact and cost assessment of one-part geopolymers produced by conventional and 3D printing methods are also discussed and compared to OPC and two-part geopolymers. This review concluded that one-part geopolymers are easier to mix and use than two-part geopolymers and have a lower carbon footprint than two-part geopolymers and OPC concrete. However, one-part geopolymers may not be as strong as two-part geopolymers, but they are still better than OPC.

3D printing technology can be of crucial importance in the design of sustainable and energy-efficient building envelopes. With this technology, there is the potential to mechanically and thermally optimise the topology of printed walls. Additionally, the printing and infill materials used can be insulating, and thus contributing to the overall reduction of heat loss. To date, limited examples of 3D printed envelopes and information about the thermal and mechanical performance of 3D printed walls are available. This study developed a 3D printable wall element with an insulating property for application in building envelopes. Seven wall topologies are studied through simulations of mechanical and thermal performance using two mixtures: a control mixture (normal-weight) and a lightweight mixture containing expanded thermoplastic microspheres (ETM) for thermal insulation. One wall topology is selected based on the performance of the simulation and printed using both mixtures. The 3D printed envelopes were tested under compressive strength and analysed with the ARAMIS system, a digital image correlation (DIC) technology. Computer simulations and the DIC analysis identified the main causes for failure, which are the inter-filament weakness and the imperfections of the geometry of the printed envelope.

The rapid development in 3D printing applications requires exploring a sustainable printable mixture to decrease the environmental impact induced by the existing Ordinary Portland Cement (OPC) mixtures and enable 3D printing technology to reach its peak efficiency. The high-volume substitution of OPC with supplementary cementitious materials (SCMs) is of significant interest as a promising solution for developing low-carbon feedstock for 3D printing. Yet, those materials share the problem of limited availability. The combination of limestone and calcined clay could be a promising alternative, offering various benefits, including replacing OPC in high ratios. This paper reviews 3D printable limestone calcined clay cement (LC3) mixtures, compositions, and chemical behaviour. The effect of different sand-to-binder ratios, additives content, OPC replacement levels, clay grade and calcination, and admixtures on the fresh, hardened and printing properties of the 3D printed mixtures are critically discussed. The environmental impact and production cost of the LC3 system compared to OPC and other systems are also critically evaluated along with the applications, future directions and research gaps in this field. The findings of this review show that 3D printed LC3 has a similar hardened performance and better microstructure than OPC system. Moreover, cast LC3 system has 30–50% lower environmental impacts depending on the replacement level and better economic feasibility than OPC. Therefore, making it a suitable feedstock for the innovative manufacturing technology of 3D printing.

This study presents a new approach towards the production of sol-gel silica-coated Bi2O3/Gd2O3 cement additives towards the improvement of early mechanical performance and radiation attenuation. Two types of silica coatings, which varied in synthesis method and morphology, were used to coat Bi2O3/Gd2O3 structures and evaluated as a cement filler in Portland cement pastes. Isothermal calorimetry studies and early strength evaluations confirmed that both proposed coating types can overcome retarded cement hydration process, attributed to Bi2O3 presence, resulting in improved one day compressive strength by 300% and 251% (depending on coating method) when compared to paste containing pristine Bi2O3 and Gd2O3 particles. Moreover, depending on the type of chosen coating type, various rheological performances of cement pastes can be achieved. Thanks to the proposed combination of materials, both gamma-rays and slow neutron attenuation in cement pastes can be simultaneously improved. The introduction of silica coating resulted in an increment of the gamma-ray and neutron shielding thanks to the increased probability of radiation interaction. Along with the positive early age effects of the synthesized structures, the 28 day mechanical performance of cement pastes was not suppressed, and was found to be comparable to that of the control specimen. As an outcome, silica-coated structures can be successfully used in radiation-shielding cement-based composites, e.g. with demanding early age performances.

This study investigates the effects of natural and calcined halloysite clay minerals (“NH” and “CH”, respectively) on the performance of 3D printed alkali-activated materials (AAMs). Halloysite clay minerals are selected as they are low-cost and abundantly available. At first, different characterisation techniques were employed to characterise the NH and CH additives. Mechanical performance, extrusion window, and shape stability of several AAM formulations containing various dosages (0.5 wt% to 5 wt%) of the NH and CH additives were evaluated. The best-performing mixtures in terms of fresh and hardened properties namely, NH-1.5 and CH-1.5 mixtures (containing 1.5 wt% of NH and CH additives, respectively) were then selected for 3D printing. The results showed that the CH-1.5 mixture exhibited enhanced shape stability, buildability, and mechanical properties as compared to the control mixture. The flexural and compressive strengths of 3D printed CH-1.5 samples were 88% and 40%, respectively higher than those of the printed control samples. Using the CH-1.5 mixture, a twisted column with an intricate shape was printed to verify the suitability of the developed CH-modified AAM for the construction of complex structures. This study establishes the use of halloysite clay minerals as low-cost additives for enhancing the mechanical properties and printing performance of AAMs.

Due to global environmental concerns related to climate change, the need to improve the service life of structures and infrastructures is imminently urgent. Structural elements typically suffer service life reductions, leading to poor environmental sustainability and high maintenance costs. Graphene oxide nanosheets (GONSs) effectively dispersed in a cement matrix can promote hydration, refine the microstructure and improve interfacial bonding, leading to enhanced building materials’ performance, including mechanical strength and transport properties. Cement-based nanocomposites engineered with GONSs were obtained using two commercial nanofillers, a GO water suspension and a free-flowing GO nanopowder, characterized by fully comparable morphology, size and aspect ratio and different oxidation degrees (i.e., oxygen-to-carbon molar ratio), 0.55 and 0.45, respectively. The dosage of the 2D-nanofiller ranged between 0.01% and 0.2% by weight of cement. The electrical and thermal properties were assessed through electrochemical impedance spectroscopy (EIS) and a heat flow meter, respectively. The results were discussed and linked to micrometric porosity investigated by micro-computed tomography (μ-CT) and transport properties as determined by initial surface absorption test (ISAT), boil-water saturation method (BWS) and chloride ion penetration test. Extra-low dosage mortars, especially those loaded with a lower oxidation degree (i.e., 0.45GO), showed decreased permeability and improved barrier to chloride ion transport combined with enhanced thermal and electrical conductivity with respect to that of the control samples.