Unlocking the sustainable potential of 3D concrete printing with large aggregates and steam-CO₂ curing

Abstract

Three-dimensional concrete printing (3DCP) has emerged as a promising innovation in the construction industry, significantly reducing its reliance on intensive labor while minimizing material waste. Despite its benefits, a major limitation of current 3DCP practices is the high reliance on cement as the primary binder, which often exceeds 60% of the total solid content. This high cement usage contributes significantly to CO2 emissions, raising sustainability concerns. In this study, a 3D-printable concrete mix incorporating large aggregates (up to 10 mm) was developed, replacing over 7% of fine aggregate and reducing cement content to approximately 29% by weight. The effects of CO2 gas and a steam–CO2 mixture on the mechanical performance and CO2 uptake of the printed concrete were assessed. Thermogravimetric analysis was used to quantify CO2 sequestration over time. Compared to control samples without gas treatment, those exposed to the steam–CO2 mixture showed enhanced buildability, improved compressive and flexural strength, and greater CO2 uptake. The results suggest that surface spraying of the steam–CO2 mixture during the 3D printing process offers a viable and scalable approach to improving both the structural performance and environmental footprint of printed concrete elements.

Keywords

3D concrete printing / Carbon dioxide uptake / Large-aggregate printing / Steam–CO2 injection / 3DCP buildability / CO2 emission cost / Mechanical strength

Funding

This research was supported by Saudi Aramco Technologies Company (SATC) and the National Research Foundation, Prime Minister’s Office, Singapore, under its Medium- Sized Centre funding scheme for the Singapore Centre for 3D Printing.

Conflict of Interest

The authors declare that they have no competing interests.

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