Rheological, mechanical, and environmental performance of printable graphene-enhanced cementitious composites with limestone and calcined clay

As extrusion-based 3D concrete printing gains wider acceptance in construction, there is a growing imperative to incorporate supplementary cementitious materials (SCMs) into printable mixtures to address their high cement content and promote sustainability. Conventional SCMs like fly ash and slag are becoming increasingly scarce, underscoring the need for alternative solutions such as limestone and calcined clay. Additionally, the utilization of nanomaterials in printable mixtures holds potential for enhancing the mechanical properties of 3D printed structures. These properties are often compromised by interlayer interfaces and void formations during printing, resulting in lower mechanical performance compared to conventionally cast concrete. Graphene nanoplatelets (GNPs), with their high aspect ratios and exceptional mechanical characteristics, offer promising avenues for reinforcing printable cementitious composites. This study explores the rheological, mechanical, and environmental aspects of graphene-enhanced cementitious composites incorporating limestone and calcined clay. Graphene nanoplatelets (GNPs) were dispersed utilizing a surfactant-assisted sonication technique, and their dispersion characteristics were evaluated through absorbance, particle size, and zeta potential measurements. Then, the influence of varying GNP concentrations on the rheological properties of limestone-calcined clay (LC2) cementitious composites was assessed. Compressive and flexural strength tests were conducted on 3D-printed LC2 samples with different GNP ratios, alongside cast specimens for comparison. Microstructural examination of failed specimens was performed using scanning electron microscopy. Furthermore, a life cycle assessment was conducted to compare the environmental impacts of printable LC2 mixtures to conventional printable mixtures. Incorporating GNPs at a ratio of 0.05 % by weight of cement in printable LC2 mixtures enhances compressive strength by 23 %, leading to a reduction of approximately 31 % in environmental impacts compared to conventional printed mixtures.