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[Display omitted] • Natural and calcined Halloysite clay additives were characterised. • Halloysite clay additives were incorporated to modify AAMs' printing properties. • Enhanced compatibility of calcined Halloysite clay additives in the AAMs was verified. • Buildability and mechanical properties were improved in CH-modified AAMs. This study investigates the effects of natural and calcined halloysite clay minerals ("NH" and "CH", respectively) on the performance of 3D printed alkali-activated materials (AAMs). Halloysite clay minerals are selected as they are low-cost and abundantly available. At first, different characterisation techniques were employed to characterise the NH and CH additives. Mechanical performance, extrusion window, and shape stability of several AAM formulations containing various dosages (0.5 wt% to 5 wt%) of the NH and CH additives were evaluated. The best-performing mixtures in terms of fresh and hardened properties namely, NH-1.5 and CH-1.5 mixtures (containing 1.5 wt% of NH and CH additives, respectively) were then selected for 3D printing. The results showed that the CH-1.5 mixture exhibited enhanced shape stability, buildability, and mechanical properties as compared to the control mixture. The flexural and compressive strengths of 3D printed CH-1.5 samples were 88% and 40%, respectively higher than those of the printed control samples. Using the CH-1.5 mixture, a twisted column with an intricate shape was printed to verify the suitability of the developed CH-modified AAM for the construction of complex structures. This study establishes the use of halloysite clay minerals as low-cost additives for enhancing the mechanical properties and printing performance of AAMs. [ABSTRACT FROM AUTHOR]

• 3D printable mortars containing different dosages of nanosilica (NS) were developed and evaluated. • NS accelerates significantly the setting and hardening of printable mortar, while reducing its open time. • Increment of yield stress, together with an increment in NS dosage, was found to have occurred. • Optimal NS dosage results in improvement of the compressive strength and pore structure. • Incorporation of NS in the mixture resulted in improved buildability and decrement in pore anisotropy. This study presents the experimental results of an investigation on the effects of nanosilica (NS) on the material characteristics of printable mortars used for additive manufacturing. Printable cement mortars based on Ordinary Portland Cement, limestone filler and silica sand were modified with different dosages of nanosilica (from 2% to 6% by weight of binder) and its influence on their hydration, rheological, mechanical and transport properties was assessed. The study showed that NS accelerates significantly the setting and hardening of printable mortar, while reducing its open time. Moreover, an increment of yield stress, together with an increment in NS dosage, was found to have occurred. The incorporation of an optimal NS dosage results in a noticeable increase in the compressive strength and alteration of the pore structure as determined by the MIP measurements. Moreover, transport properties of the produced mortar are significantly improved due to incorporation of NS. In addition to the microstructure refinement, Micro-CT and scanning electron microscopy (SEM) studies revealed that 3D printed mortars exhibit pore anisotropy in accordance with the printing direction. However, incorporation of NS in the mixture resulted in improved buildability, thus decreasing pore anisotropy. [ABSTRACT FROM AUTHOR]