Multi-Functional Additively Constructed Honeycomb Walls for Housing and Sheltering (2024-10)¶

Honeycomb designs have become increasingly popular in additive manufacturing due to their great mechanical properties. The honeycomb infill pattern has allowed the creation of lightweight objects without sacrificing the strength of solid objects. Honeycombs have been utilized in different applications, including architecture, aerospace, and automotive. However, there is a lack of honeycomb designs within the construction industry. With the growth of concrete additive construction, there is an opportunity to introduce honeycomb designs into construction practices. This paper proposes a methodology for manufacturing multi-functional walls through additive construction. The methodology includes several key steps, from material development and quality control testing to wall assembly and experimental investigation. Two multi-functional wall segments were additively constructed, reaching a height of 1180 mm, a width of 610 mm, and a thickness of 90 mm. These measurements led to the manufacturing of seven distinct cellular sections per wall, comprising three main, two intermediate, and two end cellular units. In addition, a columnar unit was additively constructed for corner connection, featuring two vertical octagonal cells with end brackets. A preliminary wall system made up of honeycomb wall segments was assembled using various additional materials such as sealant, clamping systems, and insulative materials. Furthermore, an additional wall segment with end connections was designed and manufactured to test its load-carrying capacity. The wall segment performed well compared to wooden stud walls and showed sufficient load-carrying capacity. Unlike traditional un-reinforced concrete structures, which are brittle and experience small plastic deformations before failing, the honeycomb wall structure experienced large plastic deformation before failure due to the use of insulation foam and silicon rubber. The preliminary testing showed that the honeycomb wall system could be an alternative to traditional housing construction, especially for shelters.