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Buildings
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3D Concrete Printing: Materials, Process, Design and Application
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3D Concrete Printing: Materials, Process, Design and Application

A special issue of Buildings (ISSN 2075-5309). This special issue belongs to the section "Building Materials, and Repair & Renovation".

Deadline for manuscript submissions: closed (31 August 2023) | Viewed by 21055

Special Issue Editors

Dr. Yu Chen

E-Mail Website
Guest Editor
Department of Materials, Mechanics, Management and Design (3Md), Delft University of Technology, Delft, The Netherlands
Interests: 3D concrete printing; rheology; sustainable concrete; material characterization; microstructure; mechanical testing
Dr. Jie Xu

E-Mail Website
Guest Editor
School of Architecture, Building and Civil Engineering, Loughborough University, Loughborough, UK
Interests: 3D concrete printing; construction automation; robotic manufacturing; CAM/CAE; process and quality control; digital measurement and inspection; BIM; digital twin
Dr. Oğuzhan Çopuroğlu

E-Mail Website
Guest Editor
Department of Materials, Mechanics, Management and Design (3Md), Delft University of Technology, Delft, The Netherlands
Interests: 3D concrete printing; durability; microstructure; sustainable concrete; material characterization; forensic construction materials engineering
Dr. Zhenhua Duan

E-Mail Website
Guest Editor
School of Civil Engineering, Tongji University, Shanghai 200092, China
Interests: low-carbon concrete; sustainability; rheological properties; 3D printing; recycled aggregate; wind turbine blades
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Hongzhi Zhang

E-Mail Website
Guest Editor
School of Qilu Transportation, Shandong University, Jinan, China
Interests: material characterization; microstructure; mechanical testing; multiscale modeling; modeling and simulation; fracture mechanics; 3D concrete printing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

As one of the emerging technologies in the architectural and construction sector, 3D concrete printing (3DCP) has received extensive attention from academia and industry for its benefits to concrete construction by increasing the freedom of architectural design, eliminating formwork and reducing construction cost, time and waste.

The goal of this Special Issue is to collect high-quality papers on the latest research in 3DCP and other digital concrete technologies (e.g., layer extrusion, powder-bed, shotcrete, dynamic casting system, etc.). The guest editors welcome papers focusing on, but not limited to, the following topics:

Materials: mix design, fresh state behaviors, rheology, mechanical performance, microstructure characterization, sustainability, durability, reinforcement, modeling and numerical simulation.

Process: machine and tooling, system integration, CAD/CAM and robotics, process and quality control, alternative shaping techniques and post-processing techniques.

Design and application: case study, topology optimization, structural behavior, functional performance (e.g., thermal, acoustic, etc.), construction practice, construction management and LCA.

Dr. Yu Chen
Dr. Jie Xu
Dr. Oguzhan Copuroglu
Dr. Zhenhua Duan
Prof. Dr. Hongzhi Zhang
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Buildings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • 3D concrete printing
  • digital fabrication of concrete
  • sustainability
  • durability
  • design
  • application
  • rheology
  • microstructure
  • fresh-state behaviors
  • mechanical performance
  • processing

Published Papers (7 papers)

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Research

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13 pages, 6495 KiB  
Article
The Effect of Printing Direction on the Strength Characteristics of a 3D Printed Concrete Wall Section
by Mattias Põldaru, Karl Tammkõrv, Tanel Tuisk, Mihkel Kiviste and Raido Puust
Buildings 2023, 13(12), 2917; https://doi.org/10.3390/buildings13122917 - 23 Nov 2023
Viewed by 725
Abstract
Digital construction is expected to reduce the high volume of waste and the labour shortage in the construction sector. The properties of hardened concrete used in 3D printing depend on numerous parameters within the manufacturing process. This study collected data using 208 specimens [...] Read more.
Digital construction is expected to reduce the high volume of waste and the labour shortage in the construction sector. The properties of hardened concrete used in 3D printing depend on numerous parameters within the manufacturing process. This study collected data using 208 specimens to measure the effect of the loading direction relative to the printing direction on the strength characteristics of printed concrete. The compressive strength was not significantly affected by the directions, but showed a 30% reduction from mould-casted strength due to lesser amount of compaction in the printing process. Flexural tensile strength showed a 14% reduction in one direction, possibly caused by heterogeneity due to the use of extrusion head with a 35% smaller diameter than the width of the layer. Splitting tensile strength was 14% lower when split between the printed layers. Splitting tensile strength is possibly 5% higher when PP fibres are oriented favourably. Full article
(This article belongs to the Special Issue 3D Concrete Printing: Materials, Process, Design and Application)
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16 pages, 9536 KiB  
Article
Effects of 3D Concrete Printing Phases on the Mechanical Performance of Printable Strain-Hardening Cementitious Composites
by Anne Linde van Overmeir, Branko Šavija, Freek P. Bos and Erik Schlangen
Buildings 2023, 13(10), 2483; https://doi.org/10.3390/buildings13102483 - 29 Sep 2023
Cited by 1 | Viewed by 854
Abstract
Several studies have shown the potential of strain-hardening cementitious composites (SHCC) as a self-reinforcing printable mortar. However, papers published on the development of three-dimensional printable SHCC (3DP-SHCC) often report a discrepancy between the mechanical properties of the cast and printed specimens. This paper [...] Read more.
Several studies have shown the potential of strain-hardening cementitious composites (SHCC) as a self-reinforcing printable mortar. However, papers published on the development of three-dimensional printable SHCC (3DP-SHCC) often report a discrepancy between the mechanical properties of the cast and printed specimens. This paper evaluates the effect of each successive phase of the printing process on the mechanical properties of the composite. To this end, materials were collected at three different stages in the printing process, i.e., after each of mixing, pumping, and extruding. The collected 3DP-SHCC materials were then cast in specimen moulds and their mechanical properties after curing were obtained. The resulting findings were juxtaposed with the mechanical properties of the specimens derived from a fully printed 3DP-SHCC element, and our findings indicate that while the density and the compressive strength are not significantly influenced by the printing process, the flexural and tensile strength, along with their associated deflection and strain, are strongly affected. Additionally, this research identifies the pumping phase as the primary phase influencing the mechanical properties during the printing process. Full article
(This article belongs to the Special Issue 3D Concrete Printing: Materials, Process, Design and Application)
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24 pages, 27567 KiB  
Article
Experimental and Numerical Assessments of New Concrete Dry Connections concerning Potentials of the Robotic Subtractive Manufacturing Technique
by Abtin Baghdadi, Mahmoud Heristchian, Lukas Ledderose and Harald Kloft
Buildings 2023, 13(1), 210; https://doi.org/10.3390/buildings13010210 - 12 Jan 2023
Cited by 1 | Viewed by 2003
Abstract
The efficient utilization of robotic construction of structures requires a review of structural material, elements and details, while traditional construction methods face difficulties in producing some dry concrete joints, robotic methods can manufacture them efficiently. With the rapid advancement of new construction methods, [...] Read more.
The efficient utilization of robotic construction of structures requires a review of structural material, elements and details, while traditional construction methods face difficulties in producing some dry concrete joints, robotic methods can manufacture them efficiently. With the rapid advancement of new construction methods, more effort should be directed towards developing new types of joints manufactureable by Additive Manufacturing (AM) methods. Accordingly, considering the potentials of robotic techniques, this article proposes eight new concrete dry joints. Concrete portal frames with two identical joints at the end of the beam are cast and evaluated under bending and shear. The performance of each joint, evaluated by experimental and numerical studies based on the crack distribution and stresses, was discussed. Furthermore, various aspects of the process of robotic subtractive manufacturing of the connections are discussed through the selected printed/milled geometries; likewise, geometrical accuracy by microscanning was measured, proving this technique’s capability (methodology). Based on findings, some proposed joints that can be manufactured entirely and quickly by robotic additive and subtractive techniques structurally can produce the full strength of the monolithic reference section. The range of the capacities and initial stiffness is, accordingly, [50%, 106%] and [51%, 124%] of the monolithic elements. Full article
(This article belongs to the Special Issue 3D Concrete Printing: Materials, Process, Design and Application)
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17 pages, 12842 KiB  
Article
Analysis of Object Deformations Printed by Extrusion of Concrete Mixtures Using 3D Scanning
by Radomír Mendřický and Petr Keller
Buildings 2023, 13(1), 191; https://doi.org/10.3390/buildings13010191 - 10 Jan 2023
Cited by 6 | Viewed by 1658
Abstract
Additive technologies in construction and architecture are becoming more and more popular. Due to their advantages, concrete extrusion technologies have great potential for the future. One of the important parameters is the quality and precision achieved in the entire building process. This study [...] Read more.
Additive technologies in construction and architecture are becoming more and more popular. Due to their advantages, concrete extrusion technologies have great potential for the future. One of the important parameters is the quality and precision achieved in the entire building process. This study investigates the search for a methodology to verify the quality of three-dimensional (3D) printing from concrete mixtures not just as an indication of the resulting accuracy of the process but to monitor the behavior of the printed object in the period immediately after the printing for a period of 28 days. Research has confirmed, among other things, that one of the main causes of dimensional changes over time is shrinkage, which occurs primarily in the length and height directions of the object. The drying behavior of the material also depends on the thickness of the wall, with the thicker parts of the element shrinking more slowly than the thin and peripheral parts. The research also confirmed the hypothesis that digitization using 3D optical scanning could be used for complex three-dimensional analysis of the dimensional accuracy and dimensional stability of concrete elements produced by 3D printing. However, due to the surface structure of printed objects, specific inspection procedures need to be chosen, which are analyzed and described in this paper. Full article
(This article belongs to the Special Issue 3D Concrete Printing: Materials, Process, Design and Application)
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Review

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30 pages, 9449 KiB  
Review
Concrete Additive Manufacturing in Construction: Integration Based on Component-Related Fabrication Strategies
by Gerrit Placzek and Patrick Schwerdtner
Buildings 2023, 13(7), 1769; https://doi.org/10.3390/buildings13071769 - 11 Jul 2023
Cited by 3 | Viewed by 3391
Abstract
Additive manufacturing (AM) with concrete, also known as concrete 3D printing, is one of the most interesting approaches for disrupting the construction industry and is currently subject to numerous research activities worldwide. AM has great potential to decrease labour costs and increase the [...] Read more.
Additive manufacturing (AM) with concrete, also known as concrete 3D printing, is one of the most interesting approaches for disrupting the construction industry and is currently subject to numerous research activities worldwide. AM has great potential to decrease labour costs and increase the material efficiency and geometric complexity of non-standardised building components. Although prior investigations have shown various fields of application for AM with concrete, the full potential with respect to different structural component types has not been covered yet. With this paper, an up-to-date review of fabrication strategies for the main structural components, (1) walls, (2) columns, (3) slabs, and (4) beams, is provided to identify trends and existing challenges. Therefore, firstly, AM methods and their underlying principles and characteristics for concrete components are presented, and secondly, fabrication strategies for each AM method are shown. The investigation uncovers different AM strategies (direct part vs. indirect “permanent formwork”; in situ, on-site, or off-site), which are currently being used. As a result, future applications of AM will require a hybrid manufacturing strategy combining conventional and additive manufacturing to fully explore its potential. Full article
(This article belongs to the Special Issue 3D Concrete Printing: Materials, Process, Design and Application)
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28 pages, 3605 KiB  
Review
Effects of Different Types of Fibers on Fresh and Hardened Properties of Cement and Geopolymer-Based 3D Printed Mixtures: A Review
by Amir Ramezani, Shahriar Modaresi, Pooria Dashti, Mohammad Rasul GivKashi, Faramarz Moodi and Ali Akbar Ramezanianpour
Buildings 2023, 13(4), 945; https://doi.org/10.3390/buildings13040945 - 02 Apr 2023
Cited by 6 | Viewed by 3679
Abstract
Three-dimensional printed concrete (3DPC) is emerging as a new building material. Due to automation, this method dramatically decreases construction time and material wastage while increasing construction quality. Despite the mentioned benefits, this technology faces various issues. Among these issues, the inability to use [...] Read more.
Three-dimensional printed concrete (3DPC) is emerging as a new building material. Due to automation, this method dramatically decreases construction time and material wastage while increasing construction quality. Despite the mentioned benefits, this technology faces various issues. Among these issues, the inability to use steel bars for reinforcement and early age cracking because of the low water-to-binder ratio and high amount of binders can be mentioned. In this regard, due to the superior properties of fiber-reinforced concrete (FRC), such as high first crack strength, tensile strength, improvement ductility, and resistance to shrinkage cracking, one of the effective ways to reinforce the mixture of the 3DPC is to use fibers instead of steel bars. Regarding the mentioned issues, the effects of different fibers, such as steel, carbon fibers and so on, on fresh and mechanical properties and dimensional stabilities of hardened concrete have been reviewed. It is predicted that using fibers, especially hybrid fibers, not only covers the deficiencies of initial cracking of 3DPC, but also can be used instead of steel bars; therefore, this material can play a pivotal role in the construction industry’s future. Full article
(This article belongs to the Special Issue 3D Concrete Printing: Materials, Process, Design and Application)
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19 pages, 3217 KiB  
Review
3D Printing in Sustainable Buildings: Systematic Review and Applications in the United Arab Emirates
by Iman Ibrahim, Fatma Eltarabishi, Hadeer Abdalla and Mohamed Abdallah
Buildings 2022, 12(10), 1703; https://doi.org/10.3390/buildings12101703 - 16 Oct 2022
Cited by 11 | Viewed by 7013
Abstract
Three-dimensional printing (3DP) has been rapidly evolving to be one of the leading technology fields in the coming decades. However, as in the early years of new technologies, 3DP suffers from technical limitations and various implications. This study focuses on the applications of [...] Read more.
Three-dimensional printing (3DP) has been rapidly evolving to be one of the leading technology fields in the coming decades. However, as in the early years of new technologies, 3DP suffers from technical limitations and various implications. This study focuses on the applications of 3DP in the construction industry, emphasizing its environmental, financial, and social sustainability aspects. A systematic bibliographic analysis was carried out for the relevant publications which increased by 25-fold from 2014 to 2021. The 3D-printed construction projects in the United Arab Emirates (UAE) are presented to demonstrate the early 3DP technology penetration into its booming construction sector. The UAE case is of particular interest from a sustainability perspective due to the environmental footprint of the ample construction activities in the country, combined with the ambitious strategic plans to achieve sustainable development goals. This critical analysis shows that, despite the limited literature, 3DP could potentially be a sustainable alternative with up to 49% less environmental footprint and 78% more cost-effectiveness compared to conventional construction techniques. As the social sustainability aspect was the least addressed, this study discusses relevant social impact indicators and systematic assessment criteria. It is evident that 3DP is already reshaping the future of the built environment, especially in cases where 3DP is advantageous, such as customized designs, quick project delivery, and sustainability-oriented constructions. Full article
(This article belongs to the Special Issue 3D Concrete Printing: Materials, Process, Design and Application)
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