Perspectives on waste materials and by-products integration into 3D concrete printing (3DCP)

Research output: Contribution to journal › Review article › Contributed › peer-review

Contributors

Abstract

Three-dimensional concrete printing (3DCP) enables automated, formwork-free construction with enhanced geometrical freedom and potential reduction in material waste. However, its environmental benefits are often limited by binder-rich mix designs, which increase clinker-related CO₂ emissions and may offset gains achieved through process efficiency. The incorporation of waste-derived constituents, including construction and demolition waste, industrial residues, agricultural by-products, and selected organic materials, offers a potential pathway toward more resource-efficient and lower-carbon printable cementitious systems.This review examines the use of waste-derived materials in 3DCP with emphasis on three interrelated performance domains: printability, buildability, and functional performance. Waste incorporation modifies key fresh-state parameters, including static and dynamic yield stress, plastic viscosity, and structuration rate, through mechanisms such as particle packing, water absorption, internal curing, lubrication, and changes in hydration kinetics. Porous materials, such as recycled concrete aggregates and rice husk ash, can promote structural build-up and moisture regulation, but may also reduce workability and shorten the printable window. Conversely, spherical particles, such as fly ash, can improve particle packing and flowability, although their effects depend strongly on replacement level, fineness, and chemical compatibility.The review highlights that waste integration in 3DCP is not inherently beneficial; rather, its success depends on balancing competing rheological, mechanical, durability, and environmental requirements. Multi-waste formulations may provide greater flexibility than single-material systems by combining complementary functions such as lubrication, internal curing, and early-age structuration. Beyond fresh-state behaviour, waste-derived materials can influence interlayer bonding, thermal performance, and emerging applications such as marine ecological structures and permanent lost formwork. Finally, the review emphasizes that processing, pre-treatment, and quality control are central to managing the variability of heterogeneous waste streams. Key research needs include standardized waste characterization, coupled material–process design methods, long-term durability assessment, and life-cycle-based evaluation of waste-integrated 3DCP systems.

Details

Original languageEnglish
Article number108392
JournalCement and concrete research
Volume210
Publication statusPublished - Dec 2026
Peer-reviewedYes

Keywords

Sustainable Development Goals

Keywords

  • 3D concrete printing, Interlayer bonding, Printability, Processing, Waste utilization