Comparative Life Cycle Assessment of Large-Scale 3D Printing Utilizing Kaolinite-Based Calcium-Sulfoaluminate-Cement Concrete and Conventional Construction (2022-04)¶

3D printing (3DP) is gaining importance as an alternative mode of construction with the aim to reduce the environmental impacts of the construction sector. This study quantitively investigates the environmental impacts of large-scale 3DP in comparison to conventional construction techniques. A cradle-to-gate life cycle assessment (LCA) framework is utilized to quantify the potential environmental impacts of 3DP. The comparative LCA of large-scale 3DP and conventional construction is applied at building level, component level, and material level. The environmental impacts of the studied scenarios are calculated via Gabi database and literature. A novel concrete mix, kaolinite-based calcium sulfoaluminate cement concrete (KCSC), incorporates kaolin clay with varying wt. percentage (%) (0%, 5% and 10%) in structural elements to reduce the overall environmental impact of large-scale 3DP. The LCA analysis results show that replacing conventional masonry walls with 3D-printed KCSC walls reduces EE, GWP, and EP by ca.12%, 55%, and 4% per unit volume and by ca. 55%, 77%, and 53% per unit compressive strength, respectively of the wall panel. On the other hand, replacing conventional walls with 3D-printed KCSC walls increases AP by ca. 30% per unit volume and reduces AP by ca. 37% per unit compressive strength of the wall panel.