3D printing is becoming increasingly popular in the construction sector. 3D printing offers the potential to reduce costs, construction time and construction waste. However, due to its high cement content, 3D printable concrete more expensive to produce. The article includes a brief literature survey on the possibility of using cement and aggregate substitutes in concrete mixtures and their impact on fresh composite properties and identifies a research gap. Herein, we propose the use of waste copper slag as a replacement for cement in 3D printable concrete. We examine the effect of replacing cement with copper slag at 5 and 10% on fresh properties of cementitious mortar. The results show that copper slag improves the workability of the mixture and lowers the design yield strength up to 44%, thereby facilitating printing. Even 30% higher fresh compressive strengths were also obtained, which suggest that the buildability of mortars containing copper slag will be improved.

The production of low-emission additive manufactured cementitious composites using functionalized rock powders offers promising mechanical properties and significantly reduces cement consumption. The effect of powder functionalization on the rheological properties of the mixture remains unclear, so this study investigated how mechanical and chemical functionalization of granite powder waste affects the viscoelastic properties of a cementitious mixture for additive manufacturing. Compression tests were used to track stress-strain changes over time, while Vane and slug tests measured yield stress in mixes with 20 % and 40 % cement replaced by natural (NGP), sieved (SGP), and carbonated granite powder (CGP). The results showed that all three powders (NGP, SGP, and CGP) increased yield stress compared to the reference mix, with CGP having the smallest effect. The functionalization of granite powder may enable the creation of desirable viscoelastic mixtures using sustainable materials. We observed that functionalizing granite powder (SGP and CGP) accelerated changes in the mixture rheological properties, with yield stress increasing by up to 33 %, while NGP showed minimal impact, similar to the reference mix. Differences between the Vane and Slug test results were also identified and their limitations described.

Bleeding is a common problem in concrete slabs, and may lead to serious damage. The goal of this article is to understand the impact of alternative binders and their properties on the bleeding of concrete. Therefore, the impact of the type of binder on the bleeding process is investigated. The results show that the addition of granite powder or fly ash allows for the increased control of the bleeding process. It was found that a finer particle size distribution (PSD), an increased specific surface area (SSA), and a higher bulk density may reduce the amount of dispensed water in the concrete mix. Furthermore, the use of additives with an increased SSA leads to even a 30% reduction of the bleeding rate of mixes. The utilization of additives with a finer PSD than cement enables a 37% reduction of the bleeding rate of mixes. The influence of bleeding on compressive strength was assessed using destructive and non-destructive tests: Replacing 30% of cement with granite powder leads to a 30% reduction of concrete strength after 28 days of curing; on the other hand, replacing 30% of cement with siliceous fly ash leads to an 18% reduction of strength. Importantly, bleeding was also found to lead to the heterogeneity of the physical and mechanical properties across the concrete section. Consequently, the proper control of the bleeding process leads to more homogeneous properties of concrete across its cross-section.

Siliceous fly ash can be applied as a cement replacement material for mortars used in cement-based floor overlays. At present, there is no knowledge of the appropriate curing conditions that need to be applied on concrete floors. Moreover, previous research related to curing conditions has left research gaps related to the conditions in which such floors are cured. This study focuses on understanding the importance of the curing conditions that are typical for concrete overlays on the physical, chemical, mechanical, and microstructural properties of siliceous fly ash-modified mortars. The results indicate that curing conditions have a significant impact on these properties (particularly long-term effects). Differences were observed between siliceous fly ash-modified mortars cured in different conditions. In this research, we investigated the volume porosity, water absorption, microstructure, hydration process, pore segmentation, and strength of composites that have had cement partially replaced with the addition of fly ash. It should be noted that the use of siliceous fly ash in properly cured mortars that are applied in floor overlays could lead to a better use of green cementitious composites.