Rheological Regulation and Printability Enhancement of 3D-Printed Recycled Concrete Incorporating Calcined Oyster Shell Powder

The relationship between rheological properties and printability in 3D-printed recycled concrete incorporating calcined oyster shell powder (COSP) remains insufficiently understood. The unstable rheological behavior and insufficient buildability of 3D-printed recycled concrete limit its application in digital construction. In this study, the COSP, a marine solid waste-derived functional powder, was incorporated into 3D-printed recycled concrete to improve rheological behavior and printability. The effects of different COSP contents on rheological properties and structure build-up were assessed. In addition, MIP, XRD, and SEM analyses were used to clarify the underlying regulation mechanism. The results showed that COSP significantly improved the rheological properties of fresh paste. As the COSP content increased from 0% to 5%, the static yield stress, dynamic yield stress, and thixotropic recovery degree increased from 1703 Pa to 4561 Pa, from 92 Pa to 375 Pa, and from 56% to 87%, respectively. Meanwhile, the structural deformation rate decreased from 12.3% to 6.37%, corresponding to a reduction of approximately 48%. An appropriate COSP content also improved the mechanical properties, with the flexural strengths in the X and Y directions increasing to 5.17 MPa and 4.99 MPa, respectively, and the compressive strengths increasing to 26.04 MPa and 25.48 MPa, respectively. The microscopic performance results indicated that COSP refined the pore structure, promoted the formation of hydration products, and improved compactness. This study offers preliminary evidence for improving the printability of 3D-printed recycled concrete, while addressing the urgent environmental challenge of marine solid waste utilization and enhancing the economic feasibility and production efficiency of 3D-printed concrete.