Feasibility, Mechanical Properties, and Environmental Impact of 3D-Printed Mortar Incorporating Recycled Fine...

To address the accumulation of construction and demolition waste (W&D), this study recycled it into regenerated fine aggregate and prepared 3D-printed mortars with replacement ratios ranging from 0% to 100%. The mechanical properties of hardened specimens were tested, and the degradation mechanisms of mechanical performance were investigated through SEM, MIP, and microhardness analysis. The carbon emissions of the materials were evaluated. The results indicated that while the 3D-printed mortar exhibited excellent buildability, its compressive strength, flexural strength, and interlayer bond strength gradually decreased with increasing replacement ratio. MIP results showed that as the replacement ratio of the W&D increased from 0% to 100%, the total porosity of the 3D-printed specimens significantly increased from 14.7433% to 27.5903%. SEM and microhardness images confirmed severe ITZ deterioration, and the average ITZ width increased from 31 to 79 μm. As the W&D replacement ratio increased from 0% to 100%, the total GWP decreased from 0.4043 to 0.3800 kg CO₂-eq/kg mortar. Maximizing the utilization of W&D is key to achieving efficient utilization of solid waste. Considering printability, mechanical performance, interlayer behavior, microstructural characteristics, and environmental impact in a comprehensive manner, the 80% W&D replacement ratio can be regarded as a relatively balanced and promising selection. This work not only suggests the technical feasibility of recycling W&D in 3D printing mortar, but also proposes a sustainable pathway to reduce carbon emissions in construction.