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Purpose This paper aims to qualify traditional concrete mixtures for large-scale material extrusion in an automated, additive manufacturing process or additive construction. Design/methodology/approach A robust and viable automated additive construction process must be developed that has the capability to construct full-scale, habitable structures using materials that are readily available near the location of the construction site. Accordingly, the applicability of conventional concrete mixtures for large-scale material extrusion in an additive construction process was investigated. A qualitative test was proposed in which concrete mixtures were forced through a modified clay extruder and evaluated on performance and potential to be suitable for nozzle extrusion typical of additive construction, or 3D printing with concrete. The concrete mixtures were further subjected to the standard drop table test for flow, and the results for the two tests were compared. Finally, the concrete mixtures were tested for setting time, compressive strength and flexural strength as final indicators for usefulness in large-scale construction. Findings Conventional concrete mixtures, typically with a high percentage of coarse aggregate, were found to be unsuitable for additive construction application due to clogging in the extruder. However, reducing the amount of coarse aggregate provided concrete mixtures that were promising for additive construction while still using materials that are generally available worldwide. Originality/value Much of the work performed in additive manufacturing processes on a construction scale using concrete focuses on unconventional concrete mixtures using synthetic aggregates or no coarse aggregate at all. This paper shows that a concrete mixture using conventional materials can be suitable for material extrusion in additive construction. The use of conventional materials will reduce costs and allow for additive construction to be used worldwide.

Alkali silicate activated slag and class F fly ash‐based binders are ambient curing, structural materials that are feasible replacements for ordinary Portland cement (OPC). They exhibit advantageous mechanical properties and less environmental impact than OPC. In this work, five sodium silicate activated slag‐fly ash binder mixtures were developed and their compressive and flexural strengths were studied as a function of curing temperature and time. It was found that the strongest mixture sets at ambient temperature and had a Weibull average flexural strength of 5.7 ± 1.5 MPa and Weibull average compressive strength of 60 ± 8 MPa at 28 days. While increasing the slag/fly ash ratio accelerated the strength development, the cure time was decreased due to the formation of calcium silicate hydrate (C–S–H), calcium aluminum silicate hydrate (C–A–S–H), and (Ca,Na) based geopolymer. The density, microstructure, and phase evolution of ambient‐cured, heat‐cured, and heat‐treated binders were studied using pycnometry, scanning electron microscopy, energy dispersive X‐ray spectroscopy (SEM‐EDS), and X‐ray diffraction (XRD). Heat‐cured binders were more dense than ambient‐cured binder. No new crystalline phases evolved through 28 days in ambient‐ or heat‐cured binders.

In this paper, the use of natural pozzolan as a partial cement substitute in concrete materials is investigated. By means of a test series, four mixes using three types of natural pozzolan, as well as a Class F fly ash, are evaluated. The effectiveness of each pozzolan in controlling alkali-silica reactions has been studied. Correlations have been revealed between the mechanical properties of the proposed mixes and a Portland cement control mix. The results are also compared with industry standards for mortars made with fly ash and silica fume. The paper's findings indicate that one type of pozzolan may be used as a substitute for fly ash, but not for silica fume.

Chemical, physical, and mechanical tests were conducted to assess the feasibility of using naturally occurring pozzolan as a cement mortar additive. One test series assessed the feasibility of substituting pozzolan for a portion of cement in concrete mortar mixtures. The chemical composition of five natural pozzolans was determined. Compressive testing was conducted on specimens with varying amounts and types of pozzolan. One pozzolan was found suitable for cement replacement in Type M mortars, and one was suitable for cement replacement in Type N mortars at a different proportion. The results indicate that, within certain mixture percentage limits, partial replacement of cement with pozzolan does not compromise mortar compressive strength.A second test series evaluated four mixes prepared using three types of natural pozzolan as well as Class F fly ash. The effectiveness of each cement replacement material in controlling alkali-silica reactions was studied. Correlations were made between the mechanical properties of the proposed mixes and a Portland cement control mix. The results were also compared with industry standards for mortars made with fly ash and silica fume. Results indicate that one type of pozzolan may be used as a substitute for fly ash, but not for silica fume.

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