Skip to content

Aluminate 2K Systems in Digital Concrete (2024-08)

Process, Design, Chemistry, and Outlook

10.1016/j.cemconres.2024.107644

 Wangler Timothy,  Tao Yaxin, Das Arnesh, Mahmoudi Matineh,  Gürel Şeyma,  Flatt Robert
Journal Article - Cement and Concrete Research, Vol. 185, No. 107644

Abstract

Digital concrete is advancing due to growing economic incentives for construction automation. Achieving more sustainable concrete construction requires carbon reduction, and digital concrete technologies enable material-saving designs. By decoupling production strength from design strength, two-component (2K) systems utilizing aluminate precipitation offer the most flexibility, allowing more sustainable mixes with higher substitution levels. However, 2K aluminate systems are complex and demand a deeper understanding of their chemistry and strength buildup. This article reviews the basics of 2K aluminate systems, specifically aluminum sulfate-based and calcium aluminate cement/calcium sulfate-based systems, and their use in an inline active mixing reactor. An example reaction engineering analysis predicts the degree of reaction in a given reactor design, relating it to yield stress. The two chemical systems are compared, and future research recommendations are provided.

57 References

  1. Anton Ana-Maria, Reiter Lex, Wangler Timothy, Frangez Valens et al. (2020-12)
    A 3D Concrete Printing Prefabrication Platform for Bespoke Columns
  2. Birru Bizu, Rehman Atta, Kim Jung-Hoon (2024-06)
    Comparative Analysis of Structural Build-Up in One-Component Stiff and Two-Component Shotcrete-Accelerated Set-on-Demand Mixtures for 3D Concrete Printing
  3. Bos Freek, Menna Costantino, Pradena Mauricio, Kreiger Eric et al. (2022-03)
    The Realities of Additively Manufactured Concrete Structures in Practice
  4. Boscaro Federica, Quadranti Elia, Wangler Timothy, Mantellato Sara et al. (2022-02)
    Eco-Friendly, Set-on-Demand Digital Concrete
  5. Burger Joris, Aejmelaeus-Lindström Johan, Gürel Şeyma, Niketić Filip et al. (2023-02)
    Eggshell Pavilion:
    A Reinforced Concrete Structure Fabricated Using Robotically 3D Printed Formwork
  6. Craveiro Flávio, Nazarian Shadi, Bártolo Helena, Bartolo Paulo et al. (2020-02)
    An Automated System for 3D Printing Functionally Graded Concrete-Based Materials
  7. Dahlenburg Maximilian, Hechtl Christian, Matthäus Carla, Fottner Johannes (2022-11)
    3D Concrete Printing:
    Graded Concrete-Extrusion
  8. Das Arnesh, Reiter Lex, Mantellato Sara, Flatt Robert (2022-10)
    Early-Age Rheology and Hydration-Control of Ternary Binders for 3D Printing Applications
  9. Das Arnesh, Song Yu, Mantellato Sara, Wangler Timothy et al. (2022-04)
    Effect of Processing on the Air-Void System of 3D Printed Concrete
  10. Deshmukh Aparna, Heintzkill Reed, Huerta Rosalba, Sobolev Konstantin (2021-11)
    Rheological Response of Magnetorheological Cementitious Inks Tuned for Active Control in Digital Construction
  11. Esnault Vivien, Labyad A., Chantin Marjorie, Toussaint Fabrice (2018-09)
    Experience in On-Line Modification of Rheology and Strength Acquisition of 3D Printable Mortars
  12. Flatt Robert, Wangler Timothy (2022-05)
    On Sustainability and Digital Fabrication with Concrete
  13. Huber Tobias, Burger Joris, Mata-Falcón Jaime, Kaufmann Walter (2023-03)
    Structural Design and Testing of Material-Optimized Ribbed RC Slabs with 3D Printed Formwork
  14. Jipa Mihail-Andrei, Calvo Barentin Cristian, Lydon Gearóid, Rippmann Matthias et al. (2019-10)
    3D Printed Formwork for Integrated Funicular Concrete Slabs
  15. Kanagasuntharam Sasitharan, Ramakrishnan Sayanthan, Muthukrishnan Shravan, Sanjayan Jay (2023-05)
    Effect of Magnetorheological Additives on the Buildability of 3D Concrete Printing
  16. Keita Emmanuel, Bessaies-Bey Hela, Zuo Wenqiang, Belin Patrick et al. (2019-06)
    Weak Bond Strength Between Successive Layers in Extrusion-Based Additive Manufacturing:
    Measurement and Physical Origin
  17. Kruger Jacques, Zeranka Stephan, Zijl Gideon (2019-07)
    3D Concrete Printing:
    A Lower-Bound Analytical Model for Buildability-Performance-Quantification
  18. Kruger Jacques, Zijl Gideon (2020-10)
    A Compendious Review on Lack-of-Fusion in Digital Concrete Fabrication
  19. Liu Huawei, Liu Chao, Wu Yiwen, Bai Guoliang et al. (2022-06)
    Hardened Properties of 3D Printed Concrete with Recycled Coarse Aggregate
  20. Lloret-Fritschi Ena, Quadranti Elia, Scotto Fabio, Fuhrimann Lukas et al. (2022-05)
    Additive Digital Casting:
    From Lab to Industry
  21. Lloret-Fritschi Ena, Reiter Lex, Wangler Timothy, Gramazio Fabio et al. (2017-03)
    Smart Dynamic Casting:
    Slipforming with Flexible Formwork
  22. Lloret-Fritschi Ena, Wangler Timothy, Gebhard Lukas, Mata-Falcón Jaime et al. (2020-05)
    From Smart Dynamic Casting to a Growing Family of Digital Casting Systems
  23. Ma Guowei, Buswell Richard, Silva Wilson, Wang Li et al. (2022-03)
    Technology Readiness:
    A Global Snapshot of 3D Concrete Printing and the Frontiers for Development
  24. Mata-Falcón Jaime, Bischof Patrick, Huber Tobias, Anton Ana-Maria et al. (2022-09)
    Digitally Fabricated Ribbed Concrete Floor Slabs:
    A Sustainable Solution for Construction
  25. Mechtcherine Viktor, Tittelboom Kim, Kazemian Ali, Kreiger Eric et al. (2022-04)
    A Roadmap for Quality-Control of Hardening and Hardened Printed Concrete
  26. Mohan Manu, Rahul Attupurathu, Schutter Geert, Tittelboom Kim (2021-01)
    Early-Age Hydration, Rheology and Pumping Characteristics of CSA Cement-Based 3D Printable Concrete
  27. Mohan Manu, Rahul Attupurathu, Schutter Geert, Tittelboom Kim (2020-10)
    Extrusion-Based Concrete 3D Printing from a Material Perspective:
    A State of the Art Review
  28. Mohan Manu, Rahul Attupurathu, Tittelboom Kim, Schutter Geert (2020-10)
    Rheological and Pumping Behavior of 3D Printable Cementitious Materials with Varying Aggregate Content
  29. Muthukrishnan Shravan, Ramakrishnan Sayanthan, Sanjayan Jay (2020-09)
    Effect of Microwave-Heating on Inter-Layer Bonding and Buildability of Geopolymer 3D Concrete Printing
  30. Muthukrishnan Shravan, Ramakrishnan Sayanthan, Sanjayan Jay (2022-10)
    In-Line Activation of Geopolymer-Slurry for Concrete 3D Printing
  31. Muthukrishnan Shravan, Ramakrishnan Sayanthan, Sanjayan Jay (2022-02)
    Set-on-Demand Geopolymer Using Print-Head Mixing for 3D Concrete Printing
  32. Pott Ursula, Jakob Cordula, Dorn Tobias, Stephan Dietmar (2023-07)
    Investigation of a Shotcrete-Accelerator for Targeted Control of Material-Properties for 3D Concrete Printing Injection-Method
  33. Reiter Lex, Wangler Timothy, Anton Ana-Maria, Flatt Robert (2020-05)
    Setting-on-Demand for Digital Concrete:
    Principles, Measurements, Chemistry, Validation
  34. Roussel Nicolas (2018-05)
    Rheological Requirements for Printable Concretes
  35. Roussel Nicolas, Buswell Richard, Ducoulombier Nicolas, Ivanova Irina et al. (2022-06)
    Assessing the Fresh Properties of Printable Cement-Based Materials:
    High-Potential Tests for Quality-Control
  36. Sanjayan Jay, Nematollahi Behzad (2019-02)
    3D Concrete Printing for Construction Applications
  37. Schutter Geert, Feys Dimitri (2016-11)
    Pumping of Fresh Concrete:
    Insights and Challenges
  38. Schutter Geert, Lesage Karel (2018-09)
    Active Control of Properties of Concrete:
    A (P)Review
  39. Schutter Geert, Lesage Karel, Mechtcherine Viktor, Nerella Venkatesh et al. (2018-08)
    Vision of 3D Printing with Concrete:
    Technical, Economic and Environmental Potentials
  40. Shao Lijing, Feng Pan, Zuo Wenqiang, Wang Haochuan et al. (2022-02)
    A Novel Method for Improving the Printability of Cement-Based Materials:
    Controlling the Releasing of Capsules Containing Chemical Admixtures
  41. Szabó Anna, Reiter Lex, Lloret-Fritschi Ena, Wangler Timothy et al. (2020-07)
    ACDC:
    The Admixture-Controlled Digital Casting and Its Application to Thin-Folded Concrete Structures
  42. Tao Yaxin, Dai Xiaodi, Schutter Geert, Tittelboom Kim (2023-06)
    Set-on-Demand of Alkali-Activated Slag Mixture Using Twin-Pipe Pumping
  43. Tao Yaxin, Lesage Karel, Tittelboom Kim, Yuan Yong et al. (2023-03)
    Twin-Pipe Pumping-Strategy for Stiffening-Control of 3D Printable Concrete:
    From Transportation to Fabrication
  44. Tao Yaxin, Mohan Manu, Rahul Attupurathu, Schutter Geert et al. (2023-02)
    Development of a Calcium Sulfoaluminate-Portland Cement Binary System for Twin-Pipe 3D Concrete Printing
  45. Tao Yaxin, Mohan Manu, Rahul Attupurathu, Schutter Geert et al. (2023-10)
    Influence of Rheology on Mixing Homogeneity and Mechanical Behavior of Twin-Pipe 3D Printable Concrete
  46. Tao Yaxin, Mohan Manu, Rahul Attupurathu, Schutter Geert et al. (2024-02)
    Hydration and Microstructure of Calcium-Sulfoaluminate-Portland-Cement Binder Systems for Set-on-Demand Applications
  47. Tao Yaxin, Rahul Attupurathu, Lesage Karel, Tittelboom Kim et al. (2021-11)
    Mechanical and Microstructural Properties of 3D Printable Concrete in the Context of the Twin-Pipe Pumping-Strategy
  48. Tao Yaxin, Rahul Attupurathu, Lesage Karel, Yuan Yong et al. (2021-02)
    Stiffening Control of Cement-Based Materials Using Accelerators in In-Line Mixing Processes:
    Possibilities and Challenges
  49. Tao Yaxin, Rahul Attupurathu, Mohan Manu, Tittelboom Kim et al. (2022-09)
    Blending Performance of Helical Static Mixer Used for Twin-Pipe 3D Concrete Printing
  50. Wangler Timothy, Lloret-Fritschi Ena, Reiter Lex, Hack Norman et al. (2016-10)
    Digital Concrete:
    Opportunities and Challenges
  51. Wangler Timothy, Pileggi Rafael, Gürel Şeyma, Flatt Robert (2022-03)
    A Chemical Process Engineering Look at Digital Concrete Processes:
    Critical Step Design, In-Line Mixing, and Scale-Up
  52. Weng Yiwei, Li Mingyang, Wong Teck, Tan Ming (2021-01)
    Synchronized Concrete and Bonding-Agent-Deposition-System for Inter-Layer Bond Strength Enhancement in 3D Concrete Printing
  53. Xiao Jianzhuang, Hou Shaodan, Duan Zhenhua, Zou Shuai (2023-01)
    Rheology of 3D Printable Concrete Prepared by Secondary Mixing of Ready-Mix Concrete
  54. Yue Hongfei, Zhang Zhuxian, Hua Sudong, Gao Yanan et al. (2023-09)
    Solid Waste-Based Set-on-Demand 3D Printed Concrete:
    Active Rheological-Control of Cement-Based Magneto-Rheological Fluids
  55. Zhang Yi, Ren Qiang, Dai Xiaodi, Tao Yaxin et al. (2024-03)
    A Potential Active Rheology-Control Approach for 3D Printable Cement-Based Materials:
    Coupling of Temperature and Viscosity-Modifiers
  56. Zhang Nan, Sanjayan Jay (2023-08)
    Surfactants to Enable Quick Nozzle Mixing in 3D Concrete Printing
  57. Zhang Nan, Xia Ming, Sanjayan Jay (2021-10)
    Short-Duration Near-Nozzle Mixing for 3D Concrete Printing

9 Citations

  1. Costa Gabriel, Maas Pyetra, Doerner Gabriel, Nazário Samara et al. (2026-01)
    Reducing the Cement Content in 3D Concrete Printing Mixtures Through Porcelain Polishing Residue Incorporation
  2. Kamhawi Abdallah, Lin Yuxin, Watson Christopher, Barton Kira et al. (2025-12)
    A Framework for Process Anomaly Detection in 3D Concrete Printing
  3. Márquez Álvaro, Varela Hugo, Barluenga Gonzalo (2025-09)
    Influence of Rheology Modifying Admixtures on the Buildability of 3D Printing Cement-Based Mortars
  4. Ozturk Onur, Lunsford Caleb, Strait James, Nair Sriramya (2025-08)
    Breaking Barriers in Underwater Construction:
    A Two-Stage 3D Printing System with On-Demand Material Adaptation
  5. Zhang Nan, Sanjayan Jay (2025-08)
    Concrete 3D Printing and Digital Fabrication Technologies for Bridge Construction
  6. Tao Yaxin, Wang Li, Wangler Timothy, Lesage Karel et al. (2025-05)
    A (P)Review:
    Adhesion of Printcrete for Tunnel Structures
  7. Tao Yaxin, Zhang Yi, Mohan Manu, Dai Xiaodi et al. (2025-05)
    Waste-Derived Aggregates in 3D Printable Concrete:
    Current Insights and Future Perspectives
  8. Gribonval Alice, Pierre Maxime, Ducoulombier Nicolas, Sab Karam et al. (2025-05)
    Multi-Physics Modelling of 3D-Printed Concrete Evolution in Environmental Conditions
  9. Das Arnesh, Wenger Cedric, Walpen Lukas, Flatt Robert (2025-02)
    Early-Age Hydration of Accelerated Low-Carbon Cements for Digital Fabrication

BibTeX
@article{wang_tao_das_mahm.2024.A2SiDC,
  author            = "Timothy Paul Wangler and Yaxin Tao and Arnesh Das and Matineh Mahmoudi and Şeyma Gürel and Robert Johann Flatt",
  title             = "Aluminate 2K Systems in Digital Concrete: Process, Design, Chemistry, and Outlook",
  doi               = "10.1016/j.cemconres.2024.107644",
  year              = "2024",
  journal           = "Cement and Concrete Research",
  volume            = "185",
  pages             = "107644",
}
Formatted Citation

T. P. Wangler, Y. Tao, A. Das, M. Mahmoudi, Ş. Gürel and R. J. Flatt, “Aluminate 2K Systems in Digital Concrete: Process, Design, Chemistry, and Outlook”, Cement and Concrete Research, vol. 185, p. 107644, 2024, doi: 10.1016/j.cemconres.2024.107644.

Wangler, Timothy Paul, Yaxin Tao, Arnesh Das, Matineh Mahmoudi, Şeyma Gürel, and Robert Johann Flatt. “Aluminate 2K Systems in Digital Concrete: Process, Design, Chemistry, and Outlook”. Cement and Concrete Research 185 (2024): 107644. https://doi.org/10.1016/j.cemconres.2024.107644.