A review of 3D concrete printing systems and materials properties: current status and future research prospects

Abstract

Purpose -Three-dimensional printing of concrete (3DPC) has a potential for the rapid industrialization of the housing sector, with benefits of reduced construction time due to no formwork requirement, ease of construction of complex geometries, potential high construction quality and reduced waste. Required materials adaption for 3DPC is within reach, as concrete materials technology has reached the point where performancebased specification is possible by specialists. This paper aims to present an overview of the current status of 3DPC for construction, including existing printing methods and material properties required for robustness of 3DPC structures or structural elements. Design/methodology/approach -This paper has presented an overview of three categories of 3DPC systems, namely, gantry, robotic and crane systems. Material compositions as well as fresh and hardened properties of mixes currently used for 3DPC have been elaborated. Findings -This paper presents an overview of the state of the art of 3DPC systems and materials. Research needs, including reinforcement in the form of bars or fibres in the 3D printable cement-based materials, are also addressed. Originality/value -The critical analysis of the 3D concrete printing system and materials described in this review paper is original.

A critical review of 3D printing in construction: benefits, challenges, and risks

“…A study conducted using this type of concrete has been found to have favorable characteristics and therefore satisfies the requirements of most structural applications [61]. This type of concrete has been reinforced with steel; however, other fibers, such as glass or carbon fibers, can also be used for reinforcement [25].…”

“…Reinforcement remains one of the challenges of 3D printing in construction. One method of reinforcement of 3D-printed structures is placing the reinforcing steel bars manually between the layers before or during printing [25]. However, this method is challenging since the steel rebar creates an obstacle for the movement of the printer head.…”

“…Another method of reinforcing that is more suited for 3D printing is by using fiber-reinforced concrete, instead. This method would fully automate the process and offers greater geometrical accuracy, reduced manufacturing time as well as a decrease in labor cost [25]. An ultra-high-performance fiber-reinforced concrete, which is reinforced with steel fibers, has been developed.…”

“…Camacho et al [14] reviewed several applications of 3D printing in construction with a focus on mechanical systems and materials and offered future directions related to onsite implementation. Paul et al [25] offered a review of 3D concrete printing with a focus on the printing systems and materials properties including the use of reinforcement bars or fibers. Additionally, Ghaffar et al [26] reviewed the systems and materials for 3D printing and discussed the sustainability-related benefits.…”

The Viability and Simplicity of 3D-Printed Construction: A Military Case Study

“…The downside of 3D-printed construction is the lack of codes and standards regulating the industry-existing design and construction standards are not applicable to 3D printing methods [15]. However, the importance of codes and standards tends to diminish in remote, isolated, or expeditionary environments due to the need to build structures as expediently as possible, thus, this is likely not a serious concern.…”