Abstract
Lightweight mortar extrusion enables the production of monolithic exterior wall components with improved thermal insulation by installing air chambers and reduced material demand compared to conventional construction techniques. However, without reinforcement, the systems are not capable of bearing high flexural forces and, thus, the application possibilities are limited. Furthermore, the layer bonding is a weak spot in the system. We investigate a reinforcement strategy combining fibers in the mortar matrix with vertically inserted elements to compensate the layer bonding. By implementing fibers in the extruded matrix, the flexural strength can be increased almost threefold parallel to the layers. However, there is still an anisotropy between the layers as fibers are oriented during deposition and the layer bond is still mainly depending on hydration processes. This can be compensated by the vertical insertion of reinforcement elements in the freshly deposited layers. Corrugated wire fibers as well as short steel reinforcement elements were suitable to increase the flexural strength between the layers. As shown, the potential increase in flexural strength could be of a factor six compared to the reference (12 N/mm2 instead of 1.9 N/mm2). Thus, the presented methods reduce anisotropy in flexural strength due to layered production.
Highlights
The aim of this paper is to evaluate the potentials of different reinforcement concepts—namely, micro steelfibers in the matrix as well as vertical and horizontal reinforcement with fibers/rebars—for the extrusion of lightweight mortar and to analyze their mode of action and integration into the printing process
The material must be suitable for extrusion
We want to compare the characteristics of the samples with micro steelfibers extruded section, we want to compare the characteristics of the samples with micro steelfibers extruded with with the lightweight mortar and the deposition of horizontal reinforcement elements between two the lightweight mortar and the deposition of horizontal reinforcement elements between two layers layers with unreinforced samples
Summary
The extrusion of lightweight mortar poses new possibilities in building construction. Structures can be optimized for the building envelope by integrating (a) a material with a low thermal conductivity and (b) the geometrical freedom as well as function integration of the extrusion process. Interspaces that might be filled with a loose insulation material or closed hollow air voids can be integrated in the structure without increasing time and effort. This way, the thermal conductivity is further reduced in comparison to a massive element. An efficient structural and thermal design can be realized on the basis of a virtually optimized model [1,2,3]. Placing material only where it is needed without formwork leads to a reduction of resource consumption and waste [3]
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