3D printing of calcined clay-limestone-based cementitious materials

Chen, Yu; He, Shan; Zhang, Yu; Wan, Zhi; Çopuroğlu, Oğuzhan; Schlangen, Erik

doi:10.1016/j.cemconres.2021.106553

Cited by 89 publications

(26 citation statements)

References 83 publications

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“…Figure 6 a,b exhibit the changes in fluidity and buildability of AAFS mortar with time, respectively. The spread diameter measured by the flow table has been proven to be useful for predicting the extrudability of cementitious material [ 66 , 67 ]. A larger spread diameter corresponds to a better extrudability [ 66 ].…”

Section: Resultsmentioning

confidence: 99%

“…All specimens were tested every 10 min after mixing. It has been proven that the spread diameter determined by the flow table test is related to its pumpability and extrudability [ 34 , 66 , 67 ]. In this work, it was found that the mixture with a spread diameter less than 200 mm cannot be continuously extruded from the 3D printer.…”

Section: Experimental Programmentioning

confidence: 99%

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Factors Influencing the Properties of Extrusion-Based 3D-Printed Alkali-Activated Fly Ash-Slag Mortar

et al. 2022

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The mix proportioning of extrusion-based 3D-printed cementitious material should balance printability and hardened properties. This paper investigated the effects of three key mix proportion parameters of 3D-printed alkali-activated fly ash/slag (3D-AAFS) mortar, i.e., the sand to binder (s/b) ratio, fly ash/ground granulated blast-furnace slag (FA/GGBS) ratio, and silicate modulus (Ms) of the activator, on extrudability, buildability, interlayer strength, and drying shrinkage. The results showed that the loss of extrudability and the development of buildability were accelerated by increasing the s/b ratio, decreasing the FA/GGBS ratio, or using a lower Ms activator. A rise in the s/b ratio improved the interlayer strength and reduces the drying shrinkage. Although increasing the FA/GGBS mass ratio from 1 to 3 led to a reduction of 35% in the interlayer bond strength, it decreased the shrinkage strain by half. A larger silicate modulus was beneficial to the interlayer bond strength, but it made shrinkage more serious. Moreover, a simple centroid design method was developed for optimizing the mix proportion of 3D-AAFS mortar to simultaneously meet the requirements of printability and hardened properties.

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Section: Resultsmentioning

confidence: 99%

Section: Experimental Programmentioning

confidence: 99%

Factors Influencing the Properties of Extrusion-Based 3D-Printed Alkali-Activated Fly Ash-Slag Mortar

et al. 2022

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“…The maximum number of deposited layers before collapsing was recorded as a visual indicator for this test. A similar method is used commonly in the literature to measure the buildability of a 3D printed structure [ 36 , 37 , 38 ].…”

Section: Methodsmentioning

confidence: 99%

Printability, Thermal and Compressive Strength Properties of Cementitious Materials: A Comparative Study with Silica Fume and Limestone

et al. 2022

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Over the past decade, 3D printing in the construction industry has received worldwide attention and developed rapidly. The research and development of cement and concrete products has also become quite well-established over the years, while other sustainable materials receive considerably lower attention in comparison. This study aims to investigate the influence of the two most commonly used sustainable cementitious materials i.e., silica fume and limestone powder, on printability, thermal and mechanical properties of fly ash–Portland cement blends. Ternary blends containing Portland cement, fly ash and silica fume or limestone powder are prepared, whereas phase change material (PCM) is introduced to improve the thermal behavior. Based on the rheological properties and concurrent 3D concrete printing, improved buildability of the modified mixtures is linked to their static yield stress. Anisotropic mechanical properties are observed for 3D printed specimens, while cast specimens exhibit a maximum 41% higher compressive strength due to better material compaction. It is clear from the results that addition of silica fume and limestone powder ranged from 5% to 10%, reducing the anisotropic mechanical properties (maximum 71% and 68% reduction in anisotropic factor, respectively) in the printed specimens. The PCM addition ranged from 5% to 10% and improved thermal performance of the mixtures, as measured by a decrease in thermal conductivity (9% and 13%) and an increase in volumetric heat capacity (9% and 10%), respectively. However, the PCM-containing mixtures show around 29% reduction in compressive strength, compared to the control specimen, which necessitates new material design considering matrix strengthening methods.

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“…The current work focused on powder constituent materials (cement and aggregates) of 3DPCC and has conducted an exhaustive review to collect mixture proportions. From the literature survey, 157 3DPCC mixture proportions were found in 47 references [ 34 , 44 , 45 , 46 , 47 , 48 , 49 , 50 , 51 , 52 , 53 , 54 , 55 , 56 , 57 , 58 , 59 , 60 , 61 , 62 , 63 , 64 , 65 , 66 , 67 , 68 , 69 , 70 , 71 , 72 , 73 , 74 , 75 , 76 , 76 , 77 , 78 , 79 , 80 , 81 , 82 , 83 , 84 , 85 , 86 , 87 , 88 ]. Even though 3DCP has been under scrutiny recently, the actual values, in terms of weight (kg/m 3 ) or volume (m 3 /m 3 ), of each constituent material employed in the mixture formulations were not always available in the literature; sometimes only some mixture design rat...…”

Section: Mixtures Proportionsmentioning

confidence: 99%

“…Calcined clay has also been used in 3DPCC along with LF to decrease PC content and improve fresh and hardened properties [ 44 , 55 , 56 , 116 ]. The main properties of calcined clay employed in 3DPCC are presented in Table 2 (lines 6 to 9) and Table 3 (lines 8 to 11).…”

Section: Powder Constituent Materials: Characterization and Effectmentioning

confidence: 99%

3D Construction Printing Standing for Sustainability and Circularity: Material-Level Opportunities

Fonseca¹,

Matos

2023

Materials

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Three-dimensional Cementitious materials Printing (3DCP) is a cutting-edge technology for the construction industry. Three-dimensional printed buildings have shown that a well-developed automated technology can foster valuable benefits, such as a freeform architectural design without formworks and reduced human intervention. However, scalability, commercialization and sustainability of the 3DPC technology remain critical issues. The current work presents the ecological fragility, challenges and opportunities inherent in decreasing the 3DCP environmental footprint at a material level (cementitious materials and aggregates). The very demanding performance of printable mixtures, namely in a fresh state, requires high dosages of cement and supplementary cementitious materials (SCM). Besides the heavy carbon footprint of cement production, the standard SCM availability might be an issue, especially in the longer term. One exciting option to decrease the embodied CO2 of 3DCP is, for example, to incorporate alternative and locally available SCM as partial cement replacements. Those alternative SCM can be wastes or by-products from industries or agriculture, with no added value. Moreover, the partial replacement of natural aggregate can also bring advantages for natural resource preservation. This work has highlighted the enormous potential of 3DCP to contribute to reducing the dependence on Portland cement and to manage the current colossal wastes and by-products with no added value, shifting to a Circular Economy. Though LCA analysis, mixture design revealed a critical parameter in the environmental impact of 3DCP elements or buildings. Even though cement significantly affects the LCA of 3DCP, it is crucial to achieving adequate fresh properties and rheology. From the literature survey, mixtures formulated with alternative SCM (wastes or by-products) are still restricted to rice husk ash, Municipal Solid Waste ashes and recycled powder from construction and demolition wastes. Natural aggregate replacement research has been focused on recycled fine sand, mine tailing, copper tailing, iron tailing, ornamental stone waste, recycled glass, crumb rubber, rubber powder and granules, recycled PET bottles and steel slag. However, flowability loss and mechanical strength decrease are still critical. Research efforts are needed to find low-carbon cement replacements and mix-design optimization, leading to a more sustainable and circular 3DCP while ensuring the final product performance.

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3D printing of calcined clay-limestone-based cementitious materials

Cited by 89 publications

References 83 publications

Factors Influencing the Properties of Extrusion-Based 3D-Printed Alkali-Activated Fly Ash-Slag Mortar

Factors Influencing the Properties of Extrusion-Based 3D-Printed Alkali-Activated Fly Ash-Slag Mortar

Printability, Thermal and Compressive Strength Properties of Cementitious Materials: A Comparative Study with Silica Fume and Limestone

3D Construction Printing Standing for Sustainability and Circularity: Material-Level Opportunities

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