Large Particle 3D Concrete Printing-A Green and Viable Solution

Area of Science:

• Materials Science
• Sustainable Construction
• Additive Manufacturing

Background:

• Conventional 3D concrete printing relies on fine aggregates, leading to high cement content and environmental concerns.
• The need for sustainable and high-performance 3D printable concrete materials is critical for widespread adoption.

Purpose of the Study:

• To introduce and investigate the Large Particle 3D Concrete Printing (LP3DCP) process.
• To evaluate the potential of incorporating large aggregates (up to 36 mm) for reduced cement usage and enhanced material properties.

Main Methods:

• Utilized a particle bed 3D printing approach with selective binding via shotcrete technique.
• Conducted material investigations on particle packing, matrix penetration, and compressive strength.
• Performed geometry studies and produced a one cubic meter demonstrator with reinforcement and subtractive processing.

Main Results:

• Reduced cement volume fraction by over 50% compared to conventional mortar printing.
• Achieved approximately 30% reduction in global warming potential, acidification potential, and non-renewable primary energy.
• Attained compressive strengths up to 65 MPa due to increased aggregate proportion.

Conclusions:

• LP3DCP offers a sustainable alternative to conventional 3D concrete printing by significantly lowering environmental impact.
• The process enables the production of high-strength, complex structures with reduced material costs.
• LP3DCP holds substantial potential for future construction applications and architectural designs.