3D Printed Concrete: Fresh and Hardened Properties

Abstract

3D concrete printing (3D CP) is an advanced form of additive manufacturing (AM), that allows for the creation of complex geometrical structures using concrete. This technology has the potential to reduce construction time and labour costs while minimizing material waste. However, there are also challenges related to material properties, structural integrity, and standardization of construction practices. The primary challenge in developing 3D printable cementitious materials lies in engineering specific fresh properties that enable extrusion-based printing. Unlike cast concrete, where formwork provides dimensional stability during the printing process, the absence of formwork in 3D printing necessitates fresh mixtures with low-slump and high-thixotropy to be suitable for concrete 3D printing. Additionally, the orthotropic nature of the resulting 3D printed object due to the extrusion process impacts its mechanical properties. Therefore, this research aims to study the effect of water content and loading directions on 3D printed concrete. A pre-mix material from Sika was used in this study. Three mixes were prepared by using three different water to dry material (w/d) ratios, 0.140 l/kg, 0.145 l/kg and 0.150 l/kg. The experiments focused on analysing flowability, green strength, mechanical properties (compressive strength, flexural strength, and modulus of elasticity), water absorption, porosity, and chemical transformations at high temperatures through thermoanalytical measurement. The results showed that the mixture containing 0.145 l/kg (w/d) exhibited satisfactory 3D printability, optimal mechanical performance, lower porosities compared with mixtures 0.140 and 0.150, and same total porosity compared with cast specimen.