Performance Requirements and Optimum Mix Proportion of High-Volume Fly Ash 3D Printable Concrete

In this study, a procedure for mixture design was proposed with the aim of meeting the requirements of extrudability, buildability, and shape stability in 3D printable concrete. Optimum water/binder ratio, sand/binder ratio, binder type, utilization ratio, aggregate particle distribution and quantity, and type and utilization ratio of chemical admixtures were determined for 3D printable concrete in terms of print quality and shape stability criteria. A total of 32 different mixtures were produced. It was determined that mixtures produced using a binder content with approximately 40% fly ash, a w/b ratio of 0.35, and aggregates with Dmax of 1 mm exhibit acceptable characteristics. Investigations were also conducted into the thixotropic behavior, rheological characteristics, and mechanical properties of the mixes that were deemed acceptable. As a result, it was determined that the increase in the amount of fly ash usage positively affected the buildability of the printed layers. Additionally, the dynamic yield stress ranging from 114 to 204 Pa, viscosity ranging from 22 to 43 Pa.s, and structural build-up value ranges suitable for the production of 3D printable concrete mixtures were determined.