A Study into the Effect of Different Nozzles Shapes and Fibre-Reinforcement in 3D Printed Mortar

Anisotropy in Additively Manufactured Concrete Specimens under Compressive Loading-Quantification of the Effects of Layer Height and Fiber Reinforcement

This paper analyzes the effect of print layer heights and loading direction on the compressive response of plain and fiber-reinforced (steel or basalt fiber) 3D printed concrete. Slabs with three different layer heights (6, 13, and 20 mm) are printed, and extracted cubes are subjected to compression (i) along the direction of printing, (ii) along the direction of layer build-up, and (iii) perpendicular to the above two directions. Digital image correlation (DIC) is used as a non-contact means to acquire the strain profiles. While the 3D printed specimens show lower strengths, as compared to cast specimens, when tested in all three directions, this effect can be reduced through the use of fiber reinforcement. Peak stress and peak strain-based anisotropy coefficients, which are linearly related, are used to characterize and quantify the directional dependence of peak stress and strain. Interface-parallel cracking is found to be the major failure mechanism, and anisotropy coefficients increase with an increase in layer height, which is attributable to the increasing significance of interfacial defects. Thus, orienting the weaker interfaces appropriately, through changes in printing direction, or strengthening them through material modifications (such as fiber reinforcement) or process changes (lower layer height, enables attainment of near-isotropy in 3D printed concrete elements.

Nanomaterials as Promising Additives for High-Performance 3D-Printed Concrete: A Critical Review

Three-dimensional (3D) printed concrete (3DPC), as one of the subset of digital fabrication, has provided a revolution in the construction industry. Accordingly, scientists, experts, and researchers in both academic and industry communities are trying to improve the performance of 3DPC. The mix design of all kinds of concrete has always been the most crucial property to reach the best efficiency. Recently, many studies have been performed to incorporate nano- and micro-scale additives to ameliorate the properties of 3DPC. The current study aims to present the main design properties of 3DPC and completely cover both fresh and hardened state characteristics of 3DPC containing different nano- and micro-additives. Our observations illustrate that nanomaterials can be mainly utilized as a thickener to ameliorate the thixotropic behavior and the structural build-up of 3DPC, resulting in higher yield stress and better viscosity recovery. Furthermore, each nanomaterial, through its unique impact, can provide lower porosity and permeability as well as better mechanical strengths for 3DPC. Although much research investigate the fresh properties of 3DPC containing nano and micro additives, future studies are needed to provide better insight into the impact of these kinds of additives on the hardened characteristics of 3DPC. In addition, researchers may devote more research to address the effects of the additives discussed herein on the performance of other kinds of 3DPC such as lightweight, self-compacting, etc. It should be noted that the effect mechanism of nanomaterials on the inter-layer bond strength of 3DPC is another crucial issue that should be investigated in future studies. Furthermore, nano-scale fillers from source of waste and biomass can be attractive additives for future research to achieve high performance of sustainable 3D-printed concrete.

A Review of the Extruder System Design for Large-Scale Extrusion-Based 3D Concrete Printing

Extrusion-based 3D concrete printing (E3DCP) has been appreciated by academia and industry as the most plausible candidate for prospective concrete constructions. Considerable research efforts are dedicated to the material design to improve the extrudability of fresh concrete. However, at the time of writing this paper, there is still a lack of a review paper that highlights the significance of the mechanical design of the E3DCP system. This paper provides a comprehensive review of the mechanical design of the E3DCP extruder system in terms of the extruder system, positioning system and advanced fittings, and their effects on the extrudability are also discussed by relating to the extrusion driving forces and extrusion resistive forces which may include chamber wall shear force, shaping force, nozzle wall shear force, dead zone shear force and layer pressing force. Moreover, a classification framework of the E3DCP system as an extension of the DFC classification framework was proposed. The authors reckoned that such a classification framework could assist a more systematic E3DCP system design.

Recent Developments and Challenges of 3D-Printed Construction: A Review of Research Fronts

In the last few years, scattered experiences of the application of additive manufacturing in the construction of buildings using 3D printing with robots or automated equipment have emerged around the world. These use a variety of procedures and suggest relevant advantages for the construction industry. In order to identify the different processes and features in development in this field and to guide future research and applications, this article presents a review of the literature on the main aspects involved in the use of 3D printing in the construction sector. The review includes state-of-the-art material mixtures, printing technologies, and potential uses, as well as a novel analysis of building strategies, management systems, and benefits stated about this new approach for construction. It reveals progressive experimentation regarding diverse features, with challenges related to the consolidation of procedures and this technology’s readiness to participate in the building market.

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

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.

Foundation Piles-A New Feature for Concrete 3D Printers

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.

Additive Manufacturing Applications for Industry 4.0: A Systematic Critical Review

Additive manufacturing, including 3D printing (3DP), is one of the critical pillars of Industry 4.0 and the next construction revolution. Several countries, including China, have utilized 3DP on larger scales or real projects. However, reviews of the lessons learned from previous large-sized practices of 3DP utilization are scarce. This paper presents a few practical applications of implementing 3DP over the past decade and suggests a direction for future research work. Recent publications on 3DP practices are systematically reviewed using an interpretivist philosophical lens, and more specifically, the nozzle characteristics are focused upon. The Scopus and China National Knowledge Infrastructure (CNKI) journal databases are utilized, resulting in the examination of 54 English and 62 Chinese papers. The selected practices from Mainland China, Hong Kong, Taiwan and Macao are considered for this review. A content critical review approach is adopted, and the identified papers are critically reviewed. These papers reported key challenges and advantages from their reported practices, such as limitations in aggregate sizes, nozzle sizes, standards, post-occupancy satisfaction, final product quality, productivity challenges and other associated risks. The paper reports upon prominent limitations and signposts directions for future investigations.

3D Concrete Printing for Sustainable Construction

Despite the rapid development of 3D printing technology for cement composites, there are still a number of unsolved issues related to extrusion printing. One of them is proper mix design that allows for meeting criteria related to the printing of cementitious materials, such as pumpability, buildability, consistency on the materials, flowability and workability, simultaneously incorporating sustainable development ideas. In the case of mixes for 3D printing, the modification of the composition which increases the overall performance does not always go hand in hand with the reduction of negative environmental impact. The article presents the results of tests of eight mixtures modified with reactive and inert mineral additives designed for 3D printing. The mixes were evaluated in terms of their rheological and mechanical properties as well as environmental impact. Initial test results were verified by printing hollow columns up until collapse. Later, the differences between the compressive strength of standard samples and printed columns were determined. In order to summarize the results, a multi-faceted analysis of the properties of the mixes was carried out, introducing assessment indicators for its individual parameters. The article proves that appropriate material modification of mixes for 3D printing can significantly reduce the negative impact on the environment without hindering required 3D printing properties.

Effect of 3D Printed Spatial Reinforcement on Flexural Characteristics of Conventional Mortar

In their fourth decade of development, additive manufacturing technologies are slowly entering research programs dedicated to building materials. While the majority of research effort is focused on using 3D printing of concrete, the authors propose using the technology for creation of spatial plastic reinforcement. Obviously, the strength properties of a 3D printed polymer are much lower than those of steel. Nevertheless, the unconventional spatial shape of a 3D printed reinforcement can substitute for much of the lower mechanical performance of polymer. Flexural characteristics of a cement mortar prism specimen reinforced by hexagon spatial elements were tested and analyzed in this paper. The hexagonal geometric shape was chosen due to its high rigidness. It was proven that it is possible to efficiently reinforce concrete beams by spatial 3D printed polymer elements. Directions of needed research were pointed and discussed.

Fresh and Hardened Properties of Extrusion-Based 3D-Printed Cementitious Materials: A Review

3D-printing of cementitious materials is an innovative construction approach with which building elements can be constructed without the use of formwork. Despite potential benefits in the construction industry, it introduces various engineering challenges from the material point of view. This paper reviews the properties of extrusion-based 3D-printed cementitious materials in both fresh and hardened states. Four main properties of fresh-state printing materials are addressed: flowability, extrudability, buildability, and open time, along with hardened properties, including density, compressive strength, flexural strength, tensile bond strength, shrinkage, and cracking. Experimental testing and effective factors of each property are covered, and a mix design procedure is proposed. The main objective of this paper is to provide an overview of the recent development in 3D-printing of cementitious materials and to identify the research gaps that need further investigation.