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Development of 3D printers for concrete structures: mix proportion design approach and laboratory testing

Loan Thi Pham (Tongji University, Shanghai, China) (Haiphong University, Haiphong, Vietnam)
Thu Nguyen (Haiphong University, Haiphong, Vietnam)
Thanh Trinh (Haiphong University, Haiphong, Vietnam)
Anh Nguyen (Haiphong University, Haiphong, Vietnam)
Quang Do (Haiphong University, Haiphong, Vietnam)
Bien Bui (Haiphong University, Haiphong, Vietnam)
Jianzhuang Xiao (Tongji University, Shanghai, China)

Smart and Sustainable Built Environment

ISSN: 2046-6099

Article publication date: 30 August 2022

Issue publication date: 21 November 2023

319

Abstract

Purpose

This study deals with three major topics: (1) the developed generations of 3D concrete printers, (2) the mix design approach for cement-based materials and (3) laboratory testing.

Design/methodology/approach

The big question is how to approach and follow the trend of 3D concrete printing technology with limited conditions such as printers, technology issues and budget. Therefore, this research focused on dealing with prominent issues, including printing equipment, mixed proportion design approaches and laboratory testing methods will be presented and analyzed.

Findings

The details of three printing equipment, including a printhead, a small-scale 3D printer, a 3D concrete printer and the printing process related to Simplify and Mach3 software, will be revealed. Secondly, the classification and efficient process will be given according to the mixture proportion design method proposed. Thirdly, laboratory testing will be conducted, including extrudability, buildability and printability. Finally, some highlight conclusions are given based on the appearance and quality of the samples printed.

Research limitations/implications

Research has been carried out with cement-based materials and 3D concrete printer which adopted the screw extruders.

Practical implications

Mix design proportion method via coefficient and slump value proposed by the authors is a relatively effective and convenient method; the rheological properties, printing process and geometry of a sample are the most significant factors that decide the success of the printing work.

Social implications

Additive manufacturing, widely known as 3D printing, has recently drawn the attention of researchers worldwide for a few decades. Thanks to its capability to transform a drawing into an object, the idea of 3D printing has also attracted the attention of engineers, architects and investors.

Originality/value

(1) Mix design proportion via coefficient and slump value proposed by the authors is a relatively effective and convenient method that can be implemented simply at the laboratory or the site. (2) The ranges of coefficients by weight of the water, sand and PP fibers to binder are (0.27–0.3), (0.6–1.0) and around 0.3, respectively. The maximum sand size was smaller than 2.5 mm, and the small amount of PP fibers enhanced the quality and significantly reduced the printed samples' shrinkage. (3) The printability is affected by mix proportion and the relationship between nozzle printing speed parameter and extrusion speed of motor turning. (4) The chosen layer height recommended smaller than 0.83 times nozzle diameter is reasonable and improves adhesions and buildability. (5) The printing open time of the concrete mixture of (12–15) minutes is a barrel to promote 3D concrete printing technology and needs improvement.

Keywords

Acknowledgements

The authors would like to acknowledge the financial support from the National Natural Science Foundation of China (51950410599), the material support from Thanh Hung Concrete Joint Venture Company and the laboratory support at Haiphong University, Vietnam. The authors especially thank VIDPOL Joint Stock Company for creating the experimental equipment.

Citation

Pham, L.T., Nguyen, T., Trinh, T., Nguyen, A., Do, Q., Bui, B. and Xiao, J. (2023), "Development of 3D printers for concrete structures: mix proportion design approach and laboratory testing", Smart and Sustainable Built Environment, Vol. 12 No. 5, pp. 1056-1073. https://doi.org/10.1108/SASBE-07-2022-0137

Publisher

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Emerald Publishing Limited

Copyright © 2022, Emerald Publishing Limited

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