Additive Manufacturing of Lightweight Gypsum and Expanded Polystyrene Granulate Composite (original) (raw)
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Journal of Cleaner Production, 2019
Perlite and vermiculite are commonly used aggregates for lightweight gypsums, but they cause negative environmental impacts due to the high energy demand needed during their manufacture. Therefore, this paper studies the physical and mechanical behavior of lightweight gypsums using incorporating mixes of polystyrene wastes, both extruded (XPS) and expanded (EPS) polystyrene, in order to substitute perlite and vermiculite and achieve new materials complying with circular economy criteria. For this, and experimental plan was designed and 33 series of gypsums were prepared containing different percentages of EPS and XPS waste and also reference samples (with no additions). These samples were tested in the laboratory and the following tests were developed: dry density, superficial hardness, mechanical strengths and thermal behavior. A comparative analysis evidenced that it is viable to obtain lightweight gypsum when adding mixes of XPS and EPS waste. These gypsums containing polystyrenes comply with the current standards and have lower density than currently used lightweight gypsums and similar mechanical strengths.
General aspects of 3D printing applied to civil construction: a review
Revista Principia - Divulgação Científica e Tecnológica do IFPB
Additive manufacturing, also called 3D printing, has been gaining ground in different sectors of industry, the arts, in addition to the biomedical environment. In recent years, this has been incorporated as a research and practice niche in civil engineering. The execution of works, at the stage where the inclusion of this technology is, is crucial in understanding the variants and challenges of the process. In this sense, the present study aims to raise and discuss issues involving the 3D printing of cementitious compounds, bringing aspects of the printing system and the materials of the mixtures used, and observing the effects that these can cause on the quality and the final performance of the structure built. It is a review of the literature developed based on the search in the scientific databases ScienceDirect, Scopus, and Francis & Taylor, using selected descriptors, which resulted, after applying the inclusion and exclusion criteria, in a total of 295 findings. Among other characteristics, it was possible to perceive the predominance of the extrusion-based procedure, in addition to how the components of the different execution approaches, as well as constituents of the mixture, modify the characteristics of the product in its fresh and hardened state. In general, additive manufacturing proves to be suitable for use, with the improvements and discoveries brought by researchers an impulse for the technique to be a possible advance in the automation of the sector.
Effecting the Rheological Properties of Composites for 3D Printing Technology in Construction
Slovak Journal of Civil Engineering
The article deals with the factors that lead to the beginnings of the solidification and hardening of materials used in 3D home printing technology in construction. At the beginning, the composition of the materials as well as their essential fresh and hardened properties and the performance assumptions of such a mixture are described. Subsequently, the article discusses the main aspects of the rheology and hydration of cement composites and the use of additives such as superplasticizers, viscosity modifiers, and acceleration and retardation additives, which directly affect the onset of the setting of such materials and the strength of the resulting mixtures. Finally, we describe the printing and curing process of the extruded material, which is divided into 4 main phases from the pumping and extrusion of the material through the initial deposition of layers to a sufficient increase in strength in the required time.
Processing and Properties of Construction Materials for 3D Printing
Materials Science Forum, 2016
3D printing (3DP), commonly known as additive manufacturing (AM), is a promising technology that can fabricate three dimensional complex shape prototypes directly from computer-aided design (CAD) model without any tooling and human intervention. Owing to its peculiar characteristics, AM is widely used in many industries to assist in the design, manufacture and commercialization of a product. More recently, this technology has been extended to building and construction (B&C) application in order to mitigate some of the critical issues such as shortage of skilled labour, high production cost and construction time, health and safety concerns of the workers in the hazardous environment etc. However for successful implementation, proper selection of materials and their mix design is highly recommended, which is a challenging task. This paper summarizes the current available 3DP systems from literature and the respective materials that have been used thus far by various experts, industrie...
Additive Manufacturing in the Geopolymer Construction Technology: A Review
The Open Construction & Building Technology Journal
This research paper presents a scientific attempt of a comprehensive systematic review of three-dimensional printing in geopolymer construction technology. The concept of 3D printing is an automated manufacturing process, layer- by- layer command, with computer-aided design model to create physical objects, acquiring swift development for the last few decades. An expansion of novel Geopolymer technology has been adopted in the construction and infrastructure industries for decades. The critical challenges of construction and infrastructure industries, such as the need for architectural, holistic, and rational designs, can be dealt with 3D printing techniques. Plentiful advantages of this emerging novel technology include a reduced amount of cost, ease of construction, a lesser amount of time, freedom of design, less wastage, aptitude to create complex structures, decrease in labor requirements, etc. Accordingly, The paper discusses common 3D techniques, such as Fused Deposition Mode...
Materials
The increasing popularity of additive manufacturing technologies in the prototyping and building industry requires the application of novel, improved composite materials. In this paper, we propose the use of a novel 3D printing cement-based composite material with natural, granulated cork, and additional reinforcement using a continuous polyethylene interlayer net combined with polypropylene fibre reinforcement. Our assessment of different physical and mechanical properties of the used materials during the 3D printing process and after curing verified the applicability of the new composite. The composite exhibited orthotropic properties, and the compressive toughness in the direction of layer stacking was lower than that perpendicular to it, by 29.8% without net reinforcement, 42.6% with net reinforcement, and 42.9% with net reinforcement and an additional freeze–thaw test. The use of the polymer net as a continuous reinforcement led to decreased compressive toughness, lowering it o...
Frontiers in Built Environment, 2019
Additive manufacturing is a fabrication technology that is rapidly revolutionizing the manufacturing and construction sectors. In this paper, a review of various prototyping technologies for printing cementitious materials and selected 3D printing techniques are presented in detail. Benchmark examples are provided to compare three well-known printing techniques; inkjet printing (binder jetting), selected laser sintering (SLS), and extrusion printing (extrusion based process). A comprehensive search in the literature was conducted to identify various mix designs that could be employed when printing cementitious materials. Aspects of concrete mix design are described, and some new experiments are conducted to analyse the printability of new mixes by the authors. Future research in the area of the rheology of cementitious materials and its relationship with the structural performance of finished concretes are highlighted.
3D printed geopolymer composites: A review
The application of three-dimensional printed (3DP) technology is expected to lead to the industrial revolution 4.0, disrupting the economy and providing design customization and adaptation. The construction sector is rapidly catching up to this modern technology with the production of a 3D printer for concrete to provide a healthy work environment, economic independence, and architectural freedom. Despite the fact that 3DP concrete technology has progressed significantly in recent decades, there is an urgent need to develop appropriate 3DP materials that improve performance while reducing material consumption, which is critical for reducing carbon dioxide emissions. Geopolymers (GPs) have been found to be a promising alternative to cement-based materials for 3DP in the construction industry, which could help make it more environmentally friendly. This article comprehensively reviews the printing process, performance requirements, advantages, disadvantages, and common 3DP concrete technologies. This article also provides in-depth studies on the behaviors and characteristics of GP composites utilized in 3DP production, such as mix design, rheology, and mechanical characteristics. Besides, study developments are moving towards a comprehensive understanding of the environmental footprints and economic benefits of 3DP concrete for building applications utilizing GPs as suitable concrete materials for the emerging environmentally friendly robust concrete compound for digital constructions today. This review article also highlights knowledge gaps or potential challenges that must be overcome to progress GP composites for 3DP, as well as future study opportunities based on prior research and existing challenges.
Applications of additive manufacturing in the construction industry – A forward-looking review
Automation in Construction, 2018
Additive manufacturing (AM), also known as 3D printing, fabricates components in a layerwise fashion directly from a digital file. Many of the early applications of AM technologies have been in the aerospace, automotive, and healthcare industries. Building on the advances in AM in these industries, there are several experimental applications of AM in the construction sector. Early investigations suggest that use of AM technologies for construction have the potential to decrease labor costs, reduce material waste, and create customized complex geometries that are difficult to achieve using conventional construction techniques. However, these initial investigations do not cover the full range of potential applications for construction or exploit the rapidly maturing AM technologies for a variety of material types. This paper provides an up-to-date review of AM as it relates to the construction industry, identifies the trend of AM processes and materials being used, and discusses related methods of implementing AM and potential advancements in applications of AM. Examples of potential advancements include use of multi-materials (e.g., use of high-performance materials only in areas where they are needed), in-situ repair in locations that are difficult or dangerous for humans to access, disaster relief construction in areas with limited construction workforce and material resources, structural and non-structural elements with optimized topologies, and customized parts of high value. AM's future in the construction industry is promising, but interdisciplinary research is still needed to provide new materials, new processes, faster printing, quality assurance, and data on mechanical properties before AM can realize its full potential in infrastructure construction.
Flow and mechanical properties of 3D printed cementitious material with recycled glass aggregates
2018
Environmental sustainability has been the focus of recent construction trends. Adopting efficient construction technologies and minimizing the usage of raw materials are a few of many ways to achieve such sustainability. In the past few years, 3D printing of concrete has received considerable attention for its potential to be the next disruptive technology for construction industry. By eliminating and/or reducing the amount of in-situ construction, combined with the need for skilled personnel, 3D printing can help in achieving good quality control at construction site, which has long been an issue in traditional construction industry. Singapore is dependent on neighboring countries for raw construction materials. Using recycled materials as a substitute for aggregates not only minimizes the usage of raw materials, but also help in reducing the Singapore’s dependency on other countries in long-term. In this study, preliminary findings of a 3D printed cementitious material with recycl...