Adaptation of Low Environmental Impact Mortar Formulations for 3D Printing (2026-04)¶

The construction industry is experiencing a transformative shift with the integration of 3D printing technologies, revolutionizing traditional construction methods. The growing adoption of 3D printing offers a promising approach to minimizing material waste, reducing manufacturing costs, and improving overall efficiency. However, 3D printable mortars often require a very high cement content and high dosage of admixtures compared to conventional mortars or concretes, which increases their carbon footprint. While 3D printing presents an opportunity to reduce waste and optimize material use, this challenge highlights the need for developing low environmental impact materials that maintain the required properties for successful additive construction. In this context, our research explores the advantages of combining low environmental impact materials with 3D printing to maximize the benefits of this innovative approach while addressing the environmental concerns associated with high cement content. Specifically, we focus on designing mortars that meet the rheological, mechanical, and environmental requirements for additive construction. Key parameters such as pumpability, buildability, and extrudability are targeted by selecting eco-friendly cement, fine calcareous filler, silica fume and sand. To ensure compatibility with 3D printing processes, we employ experimental methods such as rheological characterization, extrusion trials, and buildability tests. We adapt the formulation to ensure it possesses the necessary flow, workability, and setting properties required for extrusion and layer-by-layer construction. This adaptability to the 3D printing process is crucial, as it ensures the material can be successfully printed without compromising its performance or structural integrity. This research proposes a low-impact mortar that meet the technical demands of additive manufacturing while helping to reduce the environmental footprint of the construction industry.