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Concrete 3D Printing and Digitally-Aided Fabrication (Second Volume)

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Construction and Building Materials".

Deadline for manuscript submissions: closed (30 June 2022) | Viewed by 16670

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Dr. Arnaud Perrot

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Guest Editor

IRDL, Université Bretagne Sud, Lorient, France
Interests: 3D printing; additive manufacturing; extrusion; mix design; cement-based materials; earth-based materials; rheology; porous medium
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Nowadays, the development of computer-aided design tools along with the introduction of additive manufacturing in the construction industry are becoming crucial and very dynamic research topics. First, applications have shown that digital concrete has the ability to revolutionize the way that we build. Those disruptive building methods require joint and multidisciplinary research development in terms of the mix design of printable materials, the definition of fresh state properties and rheological behaviour requirements, dedicated test methods, the structural and architectural designs of printed structures using topology optimization and simultaneous reinforcement, and robotics innovation.

Further to the success of the Special Issue of Materials on “Concrete 3D Printing and Digitally-Aided Fabrication”, we are delighted to open a new Special Issue entitled “Concrete 3D Printing and Digitally Aided Fabrication (Second Volume)”.

This second volume of the Special Issue dedicated to digital concrete focuses on new additive manufacturing methods used for concrete: the extrusion-based method, particle-based methods, shotcrete and other new techniques using digital tools. Paper topics can deal with many aspects related to the digital fabrication of concrete- and cement-based materials: processing, case study, fresh state properties and rheological requirements, testing methods, the mechanical behaviour of printed cement-based material, the structural design of printed parts and structures, and environmental and economic impacts.

This Special Issue is expected to provide a collection of articles showing an overview of recent advances in the field of concrete 3D printing and drawing future perspectives for these new revolutionizing methods.

Prof. Dr. Arnaud Perrot
Guest Editor

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Keywords

3D printing
additive manufacturing
cement-based materials
concrete
rheology
processing
computer-aided methods
extrusion
particle-bed injection
structural design
topology optimization

Published Papers (6 papers)

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Research

18 pages, 3532 KiB

Open AccessArticle

Effect of TiO₂ Nanoparticles on the Fresh Performance of 3D-Printed Cementitious Materials

by Paulo de Matos, Tuani Zat, Kiara Corazza, Emilia Fensterseifer, Rafael Sakata, Gihad Mohamad and Erich Rodríguez

Materials 2022, 15(11), 3896; https://doi.org/10.3390/ma15113896 - 30 May 2022

Cited by 10 | Viewed by 1715

Abstract

3D printing (3DP) of cementitious materials shows several advantages compared to conventional construction methods, but it requires specific fresh-state properties. Nanomaterials have been used in cement-based materials to achieve specific fresh and hardened properties, being potential candidates for 3DP applications. However, there are no reports on using TiO₂ nanoparticles (nano-TiO₂) in 3DP cementitious composites. Thus, the current work aims to assess the effect of nano-TiO₂ on the fresh performance of 3DP cementitious materials. For this purpose, nano-TiO₂ was incorporated in pastes and mortars from 0 to 1.5 wt.%. Time-resolved hydration (in situ XRD) and rheological and printing-related properties (buildability and printability) were evaluated. Results showed that nano-TiO₂ particles enhanced the cement hydration kinetics, leading to further ettringite formation up to 140 min compared to plain cement paste. Rheological measurements showed that the nano-TiO₂ incorporation progressively increased the static and dynamic stress, viscosity, and structuration rate of pastes. Furthermore, nano-TiO₂ improved the buildability of the composites, progressively increasing the maximum number of successive layers printed before failure from 11 (0 wt.% TiO₂) to 64 (1.5 wt.% TiO₂). By contrast, the nano-TiO₂ addition reduced the printability (i.e., the printable period during which the sample was able to be molded by the 3D-printing process) from 140 min (0% TiO₂) to 90 min (1.5% TiO₂). Thus, incorporating “high” nano-TiO₂ contents (e.g., >1 wt.%) was beneficial for buildability but would require a quicker 3DP process. The adoption of nano-TiO₂ contents of around 0.75–1.00% may be an interesting choice since it reduced the printability of paste by 30 min compared with the control mix but allowed for printing 24 layers (118% higher than plain mortar). Full article

(This article belongs to the Special Issue Concrete 3D Printing and Digitally-Aided Fabrication (Second Volume))

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20 pages, 8842 KiB

Open AccessArticle

X-ray CT Analysis of the Cross-Section of a 3D-Printed Deformed Layer

by Ho-Jae Lee, Eun-A Seo, Won-Woo Kim, Jun-Mo Yang and Jae-Heum Moon

Materials 2021, 14(24), 7764; https://doi.org/10.3390/ma14247764 - 15 Dec 2021

Cited by 2 | Viewed by 1823

Abstract

In this study, we experimentally analyzed the deformation shape of stacked layers developed using three-dimensional (3D) printing technology. The nozzle traveling speed was changed to 80, 90, 100, and 110 mm/s when printing the layers to analyze its effect on layer deformation. Furthermore, the cross-sectional area and the number of layers were analyzed by printing five layers with overall dimensions of 1000 (w) × 2200 (l) × 50 (h) mm (each layer was 10 mm high) using Vernier calipers. Moreover, we analyzed the interface and cross-sectional area of layers that are difficult to confirm visually using X-ray computed tomography (X-ray CT) analysis. As a result of measuring the deformation at the center of the layer, it was confirmed that the deformation was greater for lower nozzle traveling speeds. Consequently, the X-ray CT analysis verified that the layer had the same cross-sectional area irrespective of the layer printing order at the same nozzle travel speed, even if the layer was deformed. Full article

(This article belongs to the Special Issue Concrete 3D Printing and Digitally-Aided Fabrication (Second Volume))

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19 pages, 9010 KiB

Open AccessArticle

Interlayer Strength of 3D-Printed Mortar Reinforced by Postinstalled Reinforcement

by Jihun Park, Quang-The Bui, Jungwoo Lee, Changbin Joh and In-Hwan Yang

Materials 2021, 14(21), 6630; https://doi.org/10.3390/ma14216630 - 03 Nov 2021

Cited by 4 | Viewed by 1888

Abstract

This work was designed to evaluate the interlayer strength of 3D-printed mortar with postinstalled interlayer reinforcement. Two methods of postinstalled interlayer reinforcement were considered according to the amount of overlapping. The first method did not include overlapping of the interlayer reinforcement, while the second method included overlap lengths of 20 and 40 mm. Additionally, two different curing conditions were considered: air-curing conditions and water-curing conditions. The compressive, splitting tensile, and flexural tensile strengths of 3D-printed mortar specimens with different reinforcement methods and curing conditions were investigated under three loading directions. The three loading directions were defined based on the three planes of the printed specimens. The compressive, splitting tensile, and flexural tensile strengths were dependent on the loading directions. In particular, the splitting and flexural tensile strengths decreased considerably when tensile stresses acted on the interlayers of the 3D-printed mortar specimens. However, when longitudinal interlayer reinforcement penetrated the printed layers, the flexural tensile strength or interlayer bonding strength of the printed specimens increased significantly at the interlayers. In addition, mortar specimens reinforced with overlap lengths of 20 and 40 mm were investigated in this study. The flexural tensile strength or interlayer bonding strength of 3D-printed mortar decreased after treatment under air-curing conditions because the interlayers of the printed mortar formed more pores under these conditions and were more vulnerable under loading. Finally, the findings of this study suggested that interlayer reinforcement is a potential method for improving the interlayer bonding strength of 3D-printed mortar. Full article

(This article belongs to the Special Issue Concrete 3D Printing and Digitally-Aided Fabrication (Second Volume))

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19 pages, 11403 KiB

Open AccessArticle

Comparison of Properties of 3D-Printed Mortar in Air vs. Underwater

by Seong-Jin Woo, Jun-Mo Yang, Hojae Lee and Hong-Kyu Kwon

Materials 2021, 14(19), 5888; https://doi.org/10.3390/ma14195888 - 08 Oct 2021

Cited by 8 | Viewed by 2381

Abstract

Research and technological advancements in 3D concrete printing (3DCP) have led to the idea of applying it to offshore construction. The effect of gravity is reduced underwater, which can have a positive effect on 3DCP. For basic verification of this idea, this study printed and additively manufactured specimens with the same mortar mixture in air and underwater and evaluated properties in the fresh state and the hardened state. The mechanical properties were evaluated using the specimens produced by direct casting to the mold and specimens produced by extracting from the additive part through coring and cutting. The results of the experiment show that underwater 3D printing required a greater amount of printing output than in-air 3D printing for a good print quality, and buildability was improved underwater compared to that in air. In the case of the specimen layered underwater, the density and compressive strength decreased compared to the specimen layered in air. Because there are almost no effects of moisture evaporation and bleeding in water, the interlayer bond strength of the specimen printed underwater was somewhat larger than that printed in air, while there was no effect of the deposition time interval underwater. Full article

(This article belongs to the Special Issue Concrete 3D Printing and Digitally-Aided Fabrication (Second Volume))

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26 pages, 19088 KiB

Open AccessEditor’s ChoiceArticle

Foundation Piles—A New Feature for Concrete 3D Printers

by Marcin Hoffmann, Krzysztof Żarkiewicz, Adam Zieliński, Szymon Skibicki and Łukasz Marchewka

Materials 2021, 14(10), 2545; https://doi.org/10.3390/ma14102545 - 13 May 2021

Cited by 11 | Viewed by 5483

Abstract

Foundation piles that are made by concrete 3D printers constitute a new alternative way of founding buildings constructed using incremental technology. We are currently observing very rapid development of incremental technology for the construction industry. The systems that are used for 3D printing with the application of construction materials make it possible to form permanent formwork for strip foundations, construct load-bearing walls and partition walls, and prefabricate elements, such as stairs, lintels, and ceilings. 3D printing systems do not offer soil reinforcement by making piles. The paper presents the possibility of making concrete foundation piles in laboratory conditions using a concrete 3D printer. The paper shows the tools and procedure for pile pumping. An experiment for measuring pile bearing capacity is described and an example of a pile deployment model under a foundation is described. The results of the tests and analytical calculations have shown that the displacement piles demonstrate less settlement when compared to the analysed shallow foundation. The authors indicate that it is possible to replace the shallow foundation with a series of piles combined with a printed wall without locally widening it. This type of foundation can be used for the foundation of low-rise buildings, such as detached houses. Estimated calculations have shown that the possibility of making foundation piles by a 3D printer will reduce the cost of making foundations by shortening the time of execution of works and reducing the consumption of construction materials. Full article

(This article belongs to the Special Issue Concrete 3D Printing and Digitally-Aided Fabrication (Second Volume))

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18 pages, 3670 KiB

Open AccessArticle

Fresh and Rheological Performances of Air-Entrained 3D Printable Mortars

by Yeşim Tarhan and Remzi Şahin

Materials 2021, 14(9), 2409; https://doi.org/10.3390/ma14092409 - 05 May 2021

Cited by 10 | Viewed by 2125

Abstract

The effect of air-entraining admixture (AEA) on the fresh and rheological behavior of mortars designed to be used in 3D printers was investigated. Blast furnace slag, calcined kaolin clay, polypropylene fiber, and various chemical additives were used in the mortar mixtures produced with Super White Cement (CEM I 52.5 R) and quartz sand. In addition to unit weight, air content, and compressive strength tests, in order to determine the stability of 3D printable mortar elements created by extruding layer by layer without any deformation, extrudability, buildability, and open time tests were applied. Fresh and rheological properties of 3D printable mortars were also determined. It was concluded that the addition of AEA to the mortars decreased the unit weight, viscosity, yield, and compressive strength, but increased the air content, spread diameter, initial setting time, and thixotropy of 3D printable mortar. It is recommended to develop a unique chemical admixture for 3D printable mortars, considering the active ingredients of the chemical additives that affect fresh and rheological performance of mortar such as superplasticizer, viscosity modifying, and cement hydration control. Full article

(This article belongs to the Special Issue Concrete 3D Printing and Digitally-Aided Fabrication (Second Volume))

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