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.
Self-compacting concrete (SCC) is a cementitious composite which serves complex formworks without mechanical vibrations with superior deformability and high resistance to segregation. Besides, the recycled aggregate concrete (RAC) is also developing rapidly and along with the ever-increasing sustainable demand for infrastructure. The combination of the fibers, RAC, and SCC may create advantages for the construction industry. In this study, the polypropylene (PP) fiber at 0.1, 0.15, 0.2, and 0.25% volume fractions and steel fibers at 0.25, 0.5, 0.75, and 1% volume fractions are introduced into fiber-reinforced recycled aggregate selfcompacting concrete (FR-RASCC). Both fresh property and hardened mechanical performance, comprising compressive and tensile strengths and modulus of elasticity are analyzed. The fibers validate the optimal 0.1% volume fraction for PP fiber and 0.75% volume fraction for steel fiber. In addition, the results are proved to enhance the mechanical properties and reduce cracking despite the negative impact on the fresh property. Moreover, the experimental outcomes are compared with previous researches to establish the linear model, demonstrating the relationship between fiber fraction and the mechanical properties.
K E Y W O R D Sfiber-reinforced recycled aggregate self-compacting concrete, polypropylene fibers, recycled aggregate concrete, self-compacting concrete, steel fibers
Recently, 3D printing has become one of the most popular additive manufacturing technologies. This technology has been utilised to prototype trial and produced components for various applications, such as fashion, food, automotive, medical, and construction. In recent years, automation also has become increasingly prevalent in the construction field. Extrusion printing is the most successful method to print cementitious materials, but it still faces significant challenges, such as pumpability of materials, buildability, consistency in the materials, flowability, and workability. This paper investigates the properties of 3D printed fibre-reinforced cementitious mortar prisms and members in conjunction with automation to achieve the optimum mechanical strength of printed mortar and to obtain suitable flowability and consistent workability for the mixed cementitious mortar during the printing process. This study also considered the necessary trial tests, which are required to check the mechanical properties and behaviour of the proportions of the cementitious mix. Mechanical strength was measured and shown to increase when the samples were printed using fibre-reinforced mortar by means of a caulking gun, compared with the samples that were printed using the same mix delivered by a progressive cavity pump to a 6 degree-of-freedom robot. The flexural strength of the four-printed layer fibre-reinforced mortar was found to be 3.44 ± 0.11 MPa and 5.78 ± 0.02 MPa for the one-layer. Moreover, the mortar with different types of nozzles by means of caulking is printed and compared. Several experimental tests for the fresh state of the mortar were conducted and are discussed.
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