This book presents a comprehensive overview of the state of the art in additive manufacturing in the world of concrete construction.
3D Concrete Printing tackles its subject from several angles, including issues relating to concrete materials (such as their formulation or fresh-state behavior), the various printing processes that have been developed, and how to describe the mechanical behavior and architectural and structural designs of printed structures. This book also considers the transition to application and industrialization, and the relevance of these new technologies in reducing the environmental impact of the construction sector.
Finally, material characterization methodologies are presented with a view to describing the behavior of materials both before and after printing, and the modeling tools used to simulate the process are listed.
Table of Contents
Preface
Arnaud PERROT
Chapter 1 3D Concrete Printing: Technologies, Applications and Classifications 1
Arnaud PERROT, Yohan JACQUET and Sofiane AMZIANE
1.1 Introduction: the different facets of printing 1
1.2 3D printing: from digital model to physical object 2
1.2.1 From digital model to print 2
1.2.2 Printing processes 3
1.2.3 Printing processes for cementitious materials 4
1.3 3D concrete printing - application examples 5
1.3.1 Prefabrication 5
1.3.2 On-site printing 8
1.3.3 Toward the democratization of 3D concrete printing? 10
1.4 Classification of concrete printing processes 11
1.4.1 Classification proposed by Duballet and co-authors 11
1.4.2 Classification proposed by RILEM 16
1.4.3 Complementary classification 18
1.5 Printing concrete with alternative binders or without cement? 19
1.6 Conclusion 21
1.7 References 21
Chapter 2 3D Concrete Printing by Extrusion and Filament Deposition 31
Arnaud PERROT and Yohan JACQUET
2.1 Introduction 31
2.2 Major printing families 33
2.2.1 A matter of scale 33
2.2.2 Single- and two-component materials 34
2.2.3 Robotic complexity 35
2.3 Printable materials 36
2.3.1 Material behavior during printing 36
2.3.2 Material flow behavior 38
2.3.3 Material behavior at rest 39
2.3.4 Printing specifications 43
2.4 The main stages in 3D extrusion printing 43
2.4.1 Mixing 43
2.4.2 Pumping 44
2.4.3 Extrusion 46
2.4.4 Filament deposition and local stability 48
2.4.5 Overall structure stability during printing 51
2.4.6 Elastic deformation and printing precision 55
2.4.7 Material curing during and after printing 55
2.5 Conclusion 57
2.6 References 58
Chapter 3 From Laboratory to Practice: Characterizing Fresh and Cured Printed Materials 67
Nicolas DUCOULOMBIER, Victor DE BONO, Fatima Zahraa KACHKOUCH,
Yohan JACQUET and Arnaud PERROT
3.1 Introduction 67
3.2 Characterization of fresh materials 68
3.2.1 Laboratory formulation - specifications 68
3.2.2 Print control in an industrial context 77
3.3 Characterization of hardened materials 85
3.3.1 Specifications 85
3.3.2 Characterization of physical properties 85
3.3.3 Mechanical characterization of printed materials 85
3.4 Durability 91
3.5 Conclusion 93
3.6 References 93
Chapter 4 Alternative Printing Methods for Cementitious Materials 103
Alexandre PIERRE and Arnaud PERROT
4.1 Introduction 103
4.2 Methods with supports 105
4.2.1 In situ printed supports (permanent formwork) 105
4.2.2 Mobile support 109
4.2.3 Sacrificial support 110
4.3 Particle bed methods 115
4.4 Support-free methods 117
4.5 Choice of process 118
4.6 Prospects and opportunities 121
4.6.1 Dissolvable temporary supports 121
4.6.2 Selective binding of aggregates with foams 121
4.6.3 Structural reinforcements 121
4.6.4 Functionally graded materials 122
4.7 Conclusion 123
4.8 References 123
Chapter 5 Structural Applications of 3D Printing 131
Romain MESNIL, Romain DUBALLET and Olivier BAVEREL
5.1 Introduction 131
5.1.1 Structure design 131
5.1.2 Principles of structural design 133
5.1.3 Chapter organization 135
5.2 Assessment of hardened material properties 135
5.2.1 Material or micro-structure? 135
5.2.2 Toward reconciling points of view 137
5.2.3 Orthotropic or isotropic material? 138
5.2.4 Mechanical testing 140
5.2.5 Conclusion 140
5.3 Masonry 140
5.3.1 Reinforced masonry 141
5.3.2 Confined masonry 141
5.3.3 Shell structures 143
5.3.4 Link between process and structural behavior 145
5.3.5 Toward a stereotomic approach to printing 146
5.4 3D printing and reinforced concrete 147
5.4.1 Lost or collaborative formwork? 148
5.4.2 Reinforced printed concrete 150
5.4.3 Fibering printed concrete 152
5.5 Prestressing 152
5.5.1 Principle 152
5.5.2 Application 153
5.5.3 Challenges 153
5.6 Conclusion 154
5.6.1 Structural optimization and additive manufacturing 155
5.6.2 The structural language of 3D printing 155
5.7 References 156
Chapter 6 Reinforcement of Printed Structures 161
Jean-François CARON, Nicolas DUCOULOMBIER and Léo DEMONT
6.1 Introduction, a few reminders about the reinforcement of cementitious materials 161
6.1.1 Structural reinforcement of cementitious materials 162
6.1.2 Fibering of cementitious materials 163
6.2 Reinforcement methods for additively manufactured cementitious materials and structures 168
6.2.1 A posteriori reinforcements 169
6.2.2 Mortar reinforcement 171
6.2.3 In-line reinforcements 172
6.3 Details of a special in-line reinforcement, the flow-based-pultrusion concept 176
6.3.1 Technology 176
6.3.2 Prototypes and devices 176
6.3.3 Characteristics of the hardened and reinforced material 179
6.4 Conclusion and outlook 179
6.5 References 181
Chapter 7 Numerical Simulation Tools for 3D Printing 189
Duc-Phi DO, Zeinab DIAB, Sébastien RÉMOND and Dashnor HOXHA
7.1 Introduction 189
7.2 Designing the geometric model of a virtual object 190
7.3 Digital modeling of the 3D printing process 192
7.3.1 Simulation of buildability at structural scale 193
7.3.2 Simulation of the material deposition process at printed layer scale 199
7.4 Discussions on recent advances, limitations and future research directions 202
7.5 Conclusion 211
7.6 References 212
Chapter 8 Environmental Impact of 3D Concrete Printing 219
Kateryna KUZMENKO, Charlotte ROUX and Adélaïde FERRAILLE
8.1 Introduction 220
8.2 3D printing technology and case studies 221
8.2.1 3D extrusion-deposition printing 221
8.2.2 Material-saving construction elements 222
8.2.3 Case study 223
8.2.4 Study issues 226
8.3 Methodology and case studies 226
8.3.1 Life cycle assessment method 226
8.3.2. Impact model, system boundaries and FU for the
3D concrete printing process 228
8.3.3. Impact model and FU for the constructive system
3D concrete printing process 229
8.4 Results 231
8.4.1 Environmental impact on the scale of the printed material 231
8.4.2 Environmental impact of the building system 232
8.5 Discussions and prospects 234
8.5.1 Alternative materials for printing 234
8.5.2 Impact transfer 235
8.5.3 Improving the quality and quantity of available inventory data 236
8.6 Conclusion 237
8.7 Acknowledgments 237
8.8 References 237
List of Authors 241
Index 243
