Development and Holistic Suitability-Assessment of 3D Printable Mortar (2024-09)¶

In recent years, there has been a growing focus on 3D printing technology. This attention stems from recognizing that this technology is crucial in advancing sustainable and labor-efficient construction practices. In this study, robotic arms were used to print three different integrated formworks which were then to be filled with more ecological materials with different properties (fillers). The aim of this study was to investigate the competitiveness of printed integrated formworks compared to ordinary cast concrete in terms of strength, reproducibility, ecological savings, and required physical building properties. The methods used for this assessment included the strength measurement of prisms and wall elements. Furthermore, the bonding between the fillers and mortar, and the thermal properties of both, were measured. Using the thermal conductivity results, the thermal transmittance of the wall-filler-constructs was calculated. Lastly, the global warming potential (GWPs) of the wall-filler-combinations were calculated. This study shows promising results regarding the achievable strengths, which is in the range of HPCs. However, the reproducibility of bigger elements is still limited. The analysis of the physical properties showed that the printable mortar meets current thermal requirements for approval. At the same time, the material undercut the ecological footprint of comparable cast concretes substantially while also outperforming the average printed mortar. While a higher reproducibility remains desirable, overall the competitiveness with casted concrete could be achieved.