AccScience Publishing / MSAM / Volume 5 / Issue 1 / DOI: 10.36922/MSAM025330076
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ORIGINAL RESEARCH ARTICLE

Unlocking the sustainable potential of 3D concrete printing with large aggregates and steam–CO2 curing

Suvash Chandra Paul1* ,  Junghyun Lee1 ,  Yi Wei Daniel Tay1 ,  Sean Gip Lim1 ,  Jihye Jhun1 ,  Bandar A. Fadhel2 ,  Issam T. Amr2 ,  Ming Jen Tan1*
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1 Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, College of Engineering, Nanyang Technological University, Singapore
2 Saudi Aramco Research & Development Center, Dhahran, Eastern Province, Saudi Arabia
MSAM 2026, 5(1), 025330076 https://doi.org/10.36922/MSAM025330076
Received: 15 August 2025 | Accepted: 12 September 2025 | Published online: 29 October 2025
© 2025 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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Abstract

Three-dimensional concrete printing (3DCP) has emerged as a promising innovation in the construction industry, significantly reducing its reliance on intensive labor while minimizing material waste. Despite its benefits, a major limitation of current 3DCP practices is the high reliance on cement as the primary binder, which often exceeds 60% of the total solid content. This high cement usage contributes significantly to CO2 emissions, raising sustainability concerns. In this study, a 3D-printable concrete mix incorporating large aggregates (up to 10 mm) was developed, replacing over 7% of fine aggregate and reducing cement content to approximately 29% by weight. The effects of CO2 gas and a steam–CO2 mixture on the mechanical performance and CO2 uptake of the printed concrete were assessed. Thermogravimetric analysis was used to quantify CO2 sequestration over time. Compared to control samples without gas treatment, those exposed to the steam–CO2 mixture showed enhanced buildability, improved compressive and flexural strength, and greater CO2 uptake. The results suggest that surface spraying of the steam–CO2 mixture during the 3D printing process offers a viable and scalable approach to improving both the structural performance and environmental footprint of printed concrete elements.

Graphical abstract
Keywords
3D concrete printing
Carbon dioxide uptake
Large-aggregate printing
Steam–CO2 injection
3DCP buildability
CO2 emission cost
Mechanical strength
Funding
This research was supported by Saudi Aramco Technologies Company (SATC) and the National Research Foundation, Prime Minister’s Office, Singapore, under its Medium- Sized Centre funding scheme for the Singapore Centre for 3D Printing.
Conflict of interest
The authors declare that they have no competing interests.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing
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