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A Review of 3D Concrete Printing (2023-01)

Materials and Process Characterization, Economic Considerations and Environmental Sustainability

10.1016/j.jobe.2023.105863

Ahmed Ghafur
Journal Article - Journal of Building Engineering, Vol. 66

Abstract

3D printing of cementitious materials or concrete (3DCP) has developed unbelievably in past 10 years and has the potential to revolutionize the concrete industry completely in the couple of incoming decades. Compared to cast concrete, 3DCP technology has a high customizability of architectural and structural design; can reduce material consumption, minimize material waste, decrease construction time from months or days to hours; can improve sustainability, environmental impact and resolve residential crises through providing $10,000 homes. In this article, a comprehensive review for 3D printing of various materials, techniques and trending applications has been carried out. The materials used for 3DCP, mix design principles and printing process parameters has been overviewed. The factors influencing flowability, extrudability, buildability of various mixes; microstructure and mechanical properties of the hardened concrete; and improvement techniques has been discussed. An important part of this review is provided to highlight the cost of 3D printed houses compared with traditional alternatives, and environmental sustainability of 3DCP and its compatibility with international plans for climate change and minimizing the energy usage. Finally, some to-date challenges are discussed, with conclusions that also identifies the needed research and state of the art for this incredible technology. Overall, this review presents the finding of the mentioned topics through exploring 396 of the latest published articles especially focusing on last three years.

195 References

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    A Review of Large-Scale 3DCP:
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  34. Cicione Antonio, Kruger Jacques, Walls Richard, Zijl Gideon (2020-05)
    An Experimental Study of the Behavior of 3D Printed Concrete at Elevated Temperatures
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    An Automated System for 3D Printing Functionally Graded Concrete-Based Materials
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  39. Ding Tao, Xiao Jianzhuang, Qin Fei, Duan Zhenhua (2020-03)
    Mechanical Behavior of 3D Printed Mortar with Recycled Sand at Early-Ages
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    Mobile Robotic Fabrication Beyond Factory Conditions:
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    Classification of Building Systems for Concrete 3D Printing
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    An Approach to Develop Printable Strain-Hardening Cementitious Composites
  44. Fratello Virginia, Rael Ronald (2020-05)
    Innovating Materials for Large-Scale Additive Manufacturing:
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    Studying the Bond Properties of Vertical Integrated Short Reinforcement in the Shotcrete 3D Printing Process
  46. Furet Benoît, Poullain Philippe, Garnier Sébastien (2019-04)
    3D Printing for Construction Based on a Complex Wall of Polymer-Foam and Concrete
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    Aligned Inter-Layer Fiber-Reinforcement and Post-Tensioning as a Reinforcement-Strategy for Digital Fabrication
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    Structural Behavior of 3D Printed Concrete Beams with Various Reinforcement-Strategies
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    Large-Scale 3D Printing of Ultra-High-Performance Concrete:
    A New Processing Route for Architects and Builders
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    Influence of Supplementary Cementitious Materials on Rheological Properties of 3D Printed Fly-Ash-Based Geopolymer
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    Mesh Mould:
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    3D Printing of Buildings and Building Components as the Future of Sustainable Construction?
  53. Hambach Manuel, Volkmer Dirk (2017-02)
    Properties of 3D Printed Fiber-Reinforced Portland-Cement-Paste
  54. Han Yilong, Yang Zhihan, Ding Tao, Xiao Jianzhuang (2020-08)
    Environmental and Economic Assessment on 3D Printed Buildings with Recycled Concrete
  55. Hass Lauri, Bos Freek, Salet Theo (2022-09)
    Characterizing the Bond Properties of Automatically Placed Helical Reinforcement in 3D Printed Concrete
  56. Heras Murica Daniel, Genedy Moneeb, Taha Mahmoud (2020-09)
    Examining the Significance of Infill-Printing-Pattern on the Anisotropy of 3D Printed Concrete
  57. Hojati Maryam, Memari Ali, Zahabi Mehrzad, Wu Zhengyu et al. (2022-06)
    Barbed-Wire Reinforcement for 3D Concrete Printing
  58. Hosseini Ehsan, Zakertabrizi Mohammad, Korayem Asghar, Xu Guanzhong (2019-03)
    A Novel Method to Enhance the Inter-Layer Bonding of 3D Printing Concrete:
    An Experimental and Computational Investigation
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    A Review of 3D Printed Concrete:
    Performance-Requirements, Testing Measurements and Mix-Design
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    The Viability and Simplicity of 3D Printed Construction:
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    Direct-Shear-Test for the Assessment of Rheological Parameters of Concrete for 3D Printing Applications
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    Rheological Property Criteria for Buildable 3D Printing Concrete
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    A 3D Printed Ready-Mixed Concrete Power-Distribution Substation:
    Materials and Construction Technology
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    Development of a 3D Printer for Concrete Structures:
    Laboratory Testing of Cementitious Materials
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    Rheological Control of 3D Printable Cement-Paste and Mortars
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    Cementitious Materials for Construction-Scale 3D Printing:
    Laboratory Testing of Fresh Printing Mixture
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    Compound Fabrication:
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    Weak Bond Strength Between Successive Layers in Extrusion-Based Additive Manufacturing:
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    Automated Construction by Contour Crafting:
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    Mega-Scale Fabrication by Contour Crafting
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    Facilitating Ductile Failure of 3D Printed Concrete Elements in Fire
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    An Investigation into the Porosity of Extrusion-Based 3D Printed Concrete
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    A Compendious Review on Lack-of-Fusion in Digital Concrete Fabrication
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    Environmental Impact of Extrusion-Based Additive Manufacturing:
    Generic Model, Power-Measurements and Influence of Printing-Resolution
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    Additive Construction:
    State of the Art, Challenges and Opportunities
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    Hardened Properties of High-Performance Printing Concrete
  84. Le Thanh, Austin Simon, Lim Sungwoo, Buswell Richard et al. (2012-01)
    Mix-Design and Fresh Properties for High-Performance Printing Concrete
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    Correlation Between Pore Characteristics and Tensile Bond Strength of Additive Manufactured Mortar Using X-Ray Computed Tomography
  86. Li Victor, Bos Freek, Yu Kequan, McGee Wesley et al. (2020-04)
    On the Emergence of 3D Printable Engineered, Strain-Hardening Cementitious Composites
  87. Li Zhijian, Wang Li, Ma Guowei (2020-01)
    Mechanical Improvement of Continuous Steel-Micro-Cable-Reinforced Geopolymer Composites for 3D Printing Subjected to Different Loading Conditions
  88. Lim Sungwoo, Buswell Richard, Le Thanh, Austin Simon et al. (2011-07)
    Developments in Construction-Scale Additive Manufacturing Processes
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    Modelling Curved-Layered Printing Paths for Fabricating Large-Scale Construction Components
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    Improving Flexural Characteristics of 3D Printed Geopolymer Composites with In-Process Steel-Cable-Reinforcement
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    Modelling- and Parameter-Optimization for Filament-Deformation in 3D Cementitious Material-Printing Using Support-Vector-Machine
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    Mixture-Design-Approach to Optimize the Rheological Properties of the Material Used in 3D Cementitious Material-Printing
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    A Comparative Study on Environmental Performance of 3D Printing and Conventional Casting of Concrete Products with Industrial Wastes
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    From Smart Dynamic Casting to a Growing Family of Digital Casting Systems
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    Possibilities and Challenges
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    Mechanical Anisotropy of Aligned Fiber-Reinforced Composite for Extrusion-Based 3D Printing
  100. Ma Guowei, Li Yanfeng, Wang Li, Zhang Junfei et al. (2020-01)
    Real-Time Quantification of Fresh and Hardened Mechanical Property for 3D Printing Material by Intellectualization with Piezoelectric Transducers
  101. Ma Guowei, Salman Nazar, Wang Li, Wang Fang (2020-02)
    A Novel Additive Mortar Leveraging Internal Curing for Enhancing Inter-Layer Bonding of Cementitious Composite for 3D Printing
  102. Ma Guowei, Sun Junbo, Wang Li, Aslani Farhad et al. (2018-09)
    Electromagnetic and Microwave-Absorbing Properties of Cementitious Composite for 3D Printing Containing Waste Copper Solids
  103. Ma Guowei, Wang Li (2017-08)
    A Critical Review of Preparation Design and Workability Measurement of Concrete Material for Large-Scale 3D Printing
  104. Ma Guowei, Zhang Junfei, Wang Li, Li Zhijian et al. (2018-06)
    Mechanical Characterization of 3D Printed Anisotropic Cementitious Material by the Electromechanical Transducer
  105. Malaeb Zeina, Sakka Fatima, Hamzeh Farook (2019-02)
    3D Concrete Printing:
    Machine Design, Mix Proportioning, and Mix Comparison Between Different Machine Setups
  106. Marchon Delphine, Kawashima Shiho, Bessaies-Bey Hela, Mantellato Sara et al. (2018-05)
    Hydration- and Rheology-Control of Concrete for Digital Fabrication:
    Potential Admixtures and Cement-Chemistry
  107. Marchment Taylor, Sanjayan Jay (2019-10)
    Mesh Reinforcing Method for 3D Concrete Printing
  108. Marchment Taylor, Sanjayan Jay (2020-07)
    Penetration Reinforcing Method for 3D Concrete Printing
  109. Matos Paulo, Zat Tuani, Corazza Kiara, Fensterseifer Emilia et al. (2022-05)
    Effect of TiO2 Nano-Particles on the Fresh Performance of 3D Printed Cementitious Materials
  110. Mechtcherine Viktor, Bos Freek, Perrot Arnaud, Silva Wilson et al. (2020-03)
    Extrusion-Based Additive Manufacturing with Cement-Based Materials:
    Production Steps, Processes, and Their Underlying Physics
  111. Mechtcherine Viktor, Grafe Jasmin, Nerella Venkatesh, Spaniol Erik et al. (2018-05)
    3D Printed Steel-Reinforcement for Digital Concrete Construction:
    Manufacture, Mechanical Properties and Bond Behavior
  112. Mechtcherine Viktor, Michel Albert, Liebscher Marco, Schmeier Tobias (2020-06)
    Extrusion-Based Additive Manufacturing with Carbon Reinforced Concrete:
    Concept and Feasibility Study
  113. Mechtcherine Viktor, Nerella Venkatesh, Will Frank, Näther Mathias et al. (2019-08)
    Large-Scale Digital Concrete Construction:
    CONPrint3D Concept for On-Site, Monolithic 3D Printing
  114. Medicis Carolina, Gonzalez Sergio, Alvarado Yezid, Vacca Hermes et al. (2022-09)
    Mechanical Performance of Commercially Available Premix UHPC-Based 3D Printable Concrete
  115. Menna Costantino, Mata-Falcón Jaime, Bos Freek, Vantyghem Gieljan et al. (2020-04)
    Opportunities and Challenges for Structural Engineering of Digitally Fabricated Concrete
  116. Muñiz Manuel, Chantin Marjorie, Vintila Cristian, Fabritius Marc et al. (2021-02)
    Concrete Hybrid Manufacturing:
    A Machine Architecture
  117. Nair Sooraj, Alghamdi Hussam, Arora Aashay, Mehdipour Iman et al. (2019-01)
    Linking Fresh Paste Microstructure, Rheology and Extrusion-Characteristics of Cementitious Binders for 3D Printing
  118. Nair Sooraj, Panda Subhashree, Santhanam Manu, Sant Gaurav et al. (2020-05)
    A Critical Examination of the Influence of Material-Characteristics and Extruder-Geometry on 3D Printing of Cementitious Binders
  119. Nematollahi Behzad, Vijay Praful, Sanjayan Jay, Nazari Ali et al. (2018-11)
    Effect of Polypropylene Fiber Addition on Properties of Geopolymers Made by 3D Printing for Digital Construction
  120. Nerella Venkatesh, Beigh Mirza, Fataei Shirin, Mechtcherine Viktor (2018-11)
    Strain-Based Approach for Measuring Structural Build-Up of Cement-Pastes in the Context of Digital Construction
  121. Nerella Venkatesh, Hempel Simone, Mechtcherine Viktor (2019-02)
    Effects of Layer-Interface Properties on Mechanical Performance of Concrete Elements Produced by Extrusion-Based 3D Printing
  122. Nerella Venkatesh, Krause Martin, Mechtcherine Viktor (2019-11)
    Direct Printing-Test for Buildability of 3D Printable Concrete Considering Economic Viability
  123. Nerella Venkatesh, Mechtcherine Viktor (2018-03)
    Virtual Sliding-Pipe Rheometer for Estimating Pumpability of Concrete
  124. Nerella Venkatesh, Näther Mathias, Iqbal Arsalan, Butler Marko et al. (2018-09)
    In-Line Quantification of Extrudability of Cementitious Materials for Digital Construction
  125. Ngo Tuan, Kashani Alireza, Imbalzano Gabriele, Nguyen Quynh et al. (2018-02)
    Additive Manufacturing (3D Printing):
    A Review of Materials, Methods, Applications and Challenges
  126. Nodehi Mehrab, Aguayo Federico, Nodehi Shahab, Gholampour Aliakbar et al. (2022-07)
    Durability Properties of 3D Printed Concrete
  127. Pan Tinghong, Teng Huaijin, Liao Hengcheng, Jiang Yaqing et al. (2022-03)
    Effect of Shaping Plate Apparatus on Mechanical Properties of 3D Printed Cement-Based Materials:
    Experimental and Numerical Studies
  128. Panda Biranchi, Lim Jian, Tan Ming (2019-02)
    Mechanical Properties and Deformation Behavior of Early-Age Concrete in the Context of Digital Construction
  129. Panda Biranchi, Paul Suvash, Lim Jian, Tay Yi et al. (2017-08)
    Additive Manufacturing of Geopolymer for Sustainable Built Environment
  130. Panda Biranchi, Paul Suvash, Mohamed Nisar, Tay Yi et al. (2017-09)
    Measurement of Tensile Bond Strength of 3D Printed Geopolymer Mortar
  131. Panda Biranchi, Paul Suvash, Tan Ming (2017-07)
    Anisotropic Mechanical Performance of 3D Printed Fiber-Reinforced Sustainable Construction-Material
  132. Panda Biranchi, Ruan Shaoqin, Unluer Cise, Tan Ming (2018-11)
    Improving the 3D Printability of High-Volume Fly-Ash Mixtures via the Use of Nano-Attapulgite-Clay
  133. Panda Biranchi, Tan Ming (2018-03)
    Experimental Study on Mix Proportion and Fresh Properties of Fly-Ash-Based Geopolymer for 3D Concrete Printing
  134. Panda Biranchi, Tay Yi, Paul Suvash, Tan Ming (2018-05)
    Current Challenges and Future Potential of 3D Concrete Printing
  135. Panda Biranchi, Unluer Cise, Tan Ming (2018-10)
    Investigation of the Rheology and Strength of Geopolymer Mixtures for Extrusion-Based 3D Printing
  136. Panda Biranchi, Unluer Cise, Tan Ming (2019-08)
    Extrusion and Rheology Characterization of Geopolymer Nanocomposites Used in 3D Printing
  137. Park Jihun, Bui The, Lee Jungwoo, Joh Changbin et al. (2021-11)
    Inter-Layer Strength of 3D Printed Mortar Reinforced by Postinstalled Reinforcement
  138. Paul Suvash, Tay Yi, Panda Biranchi, Tan Ming (2017-08)
    Fresh and Hardened Properties of 3D Printable Cementitious Materials for Building and Construction
  139. Paul Suvash, Zijl Gideon, Tan Ming, Gibson Ian (2018-05)
    A Review of 3D Concrete Printing Systems and Materials Properties:
    Current Status and Future Research Prospects
  140. Perrot Arnaud, Jacquet Yohan, Rangeard Damien, Courteille Eric et al. (2020-03)
    Nailing of Layers:
    A Promising Way to Reinforce Concrete 3D Printing Structures
  141. Perrot Arnaud, Rangeard Damien, Nerella Venkatesh, Mechtcherine Viktor (2019-02)
    Extrusion of Cement-Based Materials:
    An Overview
  142. Perrot Arnaud, Rangeard Damien, Pierre Alexandre (2015-02)
    Structural Build-Up of Cement-Based Materials Used for 3D Printing-Extrusion-Techniques
  143. Pham Luong, Tran Jonathan, Sanjayan Jay (2020-04)
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BibTeX
@article{ahme.2023.ARo3CP,
  author            = "Ghafur H. Ahmed",
  title             = "A Review of 3D Concrete Printing: Materials and Process Characterization, Economic Considerations and Environmental Sustainability",
  doi               = "10.1016/j.jobe.2023.105863",
  year              = "2023",
  journal           = "Journal of Building Engineering",
  volume            = "66",
}
Formatted Citation

G. H. Ahmed, “A Review of 3D Concrete Printing: Materials and Process Characterization, Economic Considerations and Environmental Sustainability”, Journal of Building Engineering, vol. 66, 2023, doi: 10.1016/j.jobe.2023.105863.

Ahmed, Ghafur H.. “A Review of 3D Concrete Printing: Materials and Process Characterization, Economic Considerations and Environmental Sustainability”. Journal of Building Engineering 66 (2023). https://doi.org/10.1016/j.jobe.2023.105863.