Skip to content

Effects of Cement Mortar Characteristics on Aggregate-Bed 3D Concrete Printing (2022-07)

10.1016/j.addma.2022.103024

 Yu Shiwei,  Sanjayan Jay,  Du Hongjian
Journal Article - Additive Manufacturing, Vol. 58

Abstract

Aggregate-bed concrete printing is a variant of particle-bed concrete printing, which uses cement mortar to selectively bind coarse aggregates. This paper presents the effects of mortar properties on the printed products. The void structures of printed products were investigated by 2D image analysis and scanning electron microscopy (SEM) observation at different cross-sections. Two factors are investigated for their effects on the printing quality: the strength and the plastic viscosity of the cement mortar. Increasing mortar strength increases the strength of the skeleton between coarse aggregates and mortar. Besides, increased plastic viscosity was found to increase the volume of coarse air void (> 0.5 mm), and therefore reduce the overall strength. Based on these results, this study gives the guideline on how to adjust the sand/cement (S/C) ratio and water/cement (W/C) ratio to improve the printing qualities of aggregate-bed printing. An empirical model was then proposed considering the influence of coarse air volume and the strength of the mortar.

24 References

  1. Chen Yidong, Zhang Yunsheng, Pang Bo, Liu Zhiyong et al. (2021-05)
    Extrusion-Based 3D Printing Concrete with Coarse Aggregate:
    Printability and Direction-Dependent Mechanical Performance
  2. Fuente Albert, Blanco Ana, Galeote Eduardo, Cavalaro Sergio (2022-04)
    Structural Fiber-Reinforced Cement-Based Composite Designed for Particle-Bed 3D Printing Systems:
    Case Study Parque De Castilla Footbridge in Madrid
  3. Ji Guangchao, Ding Tao, Xiao Jianzhuang, Du Shupeng et al. (2019-05)
    A 3D Printed Ready-Mixed Concrete Power-Distribution Substation:
    Materials and Construction Technology
  4. Kruger Jacques, Plessis Anton, Zijl Gideon (2020-12)
    An Investigation into the Porosity of Extrusion-Based 3D Printed Concrete
  5. Le Thanh, Austin Simon, Lim Sungwoo, Buswell Richard et al. (2012-01)
    Hardened Properties of High-Performance Printing Concrete
  6. Liu Huawei, Liu Chao, Bai Guoliang, Wu Yiwen et al. (2022-04)
    Influence of Pore-Defects on the Hardened Properties of 3D Printed Concrete with Coarse Aggregate
  7. Liu Chao, Zhang Rongfei, Liu Huawei, He Chunhui et al. (2021-11)
    Analysis of the Mechanical Performance and Damage Mechanism for 3D Printed Concrete Based on Pore-Structure
  8. Lowke Dirk, Dini Enrico, Perrot Arnaud, Weger Daniel et al. (2018-07)
    Particle-Bed 3D Printing in Concrete Construction:
    Possibilities and Challenges
  9. Lowke Dirk, Mai (née Dressler) Inka, Keita Emmanuel, Perrot Arnaud et al. (2022-02)
    Material-Process Interactions in Particle-Bed 3D Printing and the Underlying Physics
  10. Lu Bing, Zhu Weiping, Weng Yiwei, Liu Zhixin et al. (2020-02)
    Study of MgO-Activated-Slag as a Cementless Material for Sustainable Spray-Based 3D Printing
  11. Mai (née Dressler) Inka, Brohmann Leon, Freund Niklas, Gantner Stefan et al. (2021-10)
    Large Particle 3D Concrete Printing:
    A Green and Viable Solution
  12. Mai (née Dressler) Inka, Lowke Dirk, Perrot Arnaud (2022-03)
    Fluid-Intrusion in Powder-Beds for Selective Cement-Activation:
    An Experimental and Analytical Study
  13. Mohan Manu, Rahul Attupurathu, Tittelboom Kim, Schutter Geert (2020-10)
    Rheological and Pumping Behavior of 3D Printable Cementitious Materials with Varying Aggregate Content
  14. Pierre Alexandre, Weger Daniel, Perrot Arnaud, Lowke Dirk (2018-01)
    Penetration of Cement-Pastes into Sand-Packings During 3D Printing:
    Analytical and Experimental Study
  15. Wang Xianggang, Jia Lutao, Jia Zijian, Zhang Chao et al. (2022-06)
    Optimization of 3D Printing Concrete with Coarse Aggregate via Proper Mix-Design and Printing-Process
  16. Weger Daniel, Pierre Alexandre, Perrot Arnaud, Kränkel Thomas et al. (2021-01)
    Penetration of Cement-Pastes into Particle-Beds:
    A Comparison of Penetration Models
  17. Wu Yiwen, Liu Chao, Liu Huawei, Zhang Zhenzi et al. (2021-07)
    Study on the Rheology and Buildability of 3D Printed Concrete with Recycled Coarse Aggregates
  18. Xiao Jianzhuang, Lv Zhenyuan, Duan Zhenhua, Hou Shaodan (2022-03)
    Study on Preparation and Mechanical Properties of 3D Printed Concrete with Different Aggregate-Combinations
  19. Yu Shiwei, Du Hongjian, Sanjayan Jay (2020-07)
    Aggregate-Bed 3D Concrete Printing with Cement-Paste Binder
  20. Yu Shiwei, Sanjayan Jay, Du Hongjian (2020-07)
    Impact of Particle-Size and Grading on Aggregate-Bed 3D Concrete Printing
  21. Yu Shiwei, Xia Ming, Sanjayan Jay, Yang Lin et al. (2021-07)
    Microstructural Characterization of 3D Printed Concrete
  22. Zhang Nan, Xia Ming, Sanjayan Jay (2021-10)
    Short-Duration Near-Nozzle Mixing for 3D Concrete Printing
  23. Zhang Yu, Zhang Yunsheng, She Wei, Yang Lin et al. (2019-01)
    Rheological and Hardened Properties of the High-Thixotropy 3D Printing Concrete
  24. Zhang Yu, Zhang Yunsheng, Yang Lin, Liu Guojian et al. (2021-02)
    Hardened Properties and Durability of Large-Scale 3D Printed Cement-Based Materials

31 Citations

  1. Shilar Fatheali, Shilar Mubarakali (2025-12)
    Performance-Based Analysis of 3D Printed Geopolymers Relating Durability, Microstructure, and Life Cycle Assessment
  2. Abbas Yassir, Alsaif Abdulaziz (2025-11)
    Explainable Data-Driven Modeling for Optimized Mix Design of 3D-Printed Concrete:
    Interpreting Nonlinear Synergies Among Binder Components and Proportions
  3. Niu Huaxian, Yu Bo, Hao Ji (2025-10)
    CFD-Based Flow Field Analysis of Spiral Nozzles in 3D Concrete Printing
  4. Jiang Youbau, Wen Jun, Gao Pengxiang, Liu Yan et al. (2025-09)
    Effect of Graphene Oxide on Physical and Mechanical Properties of 3D Printed Concrete
  5. Mesoudy Mouad, Rida Foulki, Driss Amegouz (2025-07)
    Addressing Geometrical and Dimensional Accuracy Challenges in 3D Concrete Printing
  6. Ramakrishnan Sayanthan, Pasupathy Kirubajiny, Manalo Allan, Sanjayan Jay (2025-07)
    Rheological, Mechanical and Fire Resistance Performance of Waste Glass Activated Geopolymers for Concrete 3D Printing
  7. Lyu Qifeng, Wang Yalun, Chen Dongjian, Liu Shiyuan et al. (2025-01)
    Energy Storage Properties and Mechanical Strengths of 3D Printed Porous Concrete Structural Supercapacitors Reinforced by Electrodes Made of Carbon-Black-Coated Ni Foam
  8. Khan Mirza, Ahmed Aayzaz, Ali Tariq, Qureshi Muhammad et al. (2024-12)
    Comprehensive Review of 3D Printed Concrete, Life Cycle Assessment, AI and ML Models:
    Materials, Engineered Properties and Techniques for Additive Manufacturing
  9. Liu Chao, Zhang Yukun, Liu Huawei, Wu Yiwen et al. (2024-10)
    Inter-Layer Reinforced 3D Printed Concrete with Recycled Coarse Aggregate:
    Shear Properties and Enhancement Methods
  10. Baytak Tugba, Gdeh Tawfeeq, Jiang Zhangfan, Arce Gabriel et al. (2024-09)
    Rheological, Mechanical, and Environmental Performance of Printable Graphene-Enhanced Cementitious Composites with Limestone and Calcined Clay
  11. An Dong, Zhang Yixia, Yang Chunhui (2024-05)
    Incorporating Coarse Aggregates into 3D Concrete Printing from Mixture Design and Process-Control to Structural Behavior and Practical Applications:
    A Review
  12. Lyu Qifeng, Wang Yalun, Dai Pengfei (2024-05)
    Multilayered Plant-Growing Concrete Manufactured by Aggregate-Bed 3D Concrete Printing
  13. Wei Ying, Han Song, Yu Shiwei, Chen Ziwei et al. (2024-05)
    Parameter Impact on 3D Concrete Printing from Single to Multi-Layer Stacking
  14. Wei Ying, Han Song, Chen Ziwei, Lu Jianxian et al. (2024-04)
    Numerical Simulation of 3D Concrete Printing Derived from Printer Head and Printing Process
  15. Geng Songyuan, Mei Liu, Cheng Boyuan, Luo Qilong et al. (2024-03)
    Revolutionizing 3D Concrete Printing:
    Leveraging Random-Forest-Model for Precise Printability and Rheological Prediction
  16. Wang Xiaonan, Li Wengui, Guo Yipu, Kashani Alireza et al. (2024-02)
    Concrete 3D Printing Technology in Sustainable Construction:
    A Review on Raw Materials, Concrete Types and Performances
  17. Nóbrega Anna, Queiroz Junior Cleanto, Souza Wendell, Cabral Kleber et al. (2024-02)
    Computational Modeling for Structural Element Analysis Using Cement Composites in 3D Printing
  18. Chen Kailun, Liu Qiong, Chen Bing, Zhang Shishun et al. (2024-01)
    A Review on Effect of Raw Materials on the Performance of 3D Printed Geopolymer System for Construction
  19. Lucen Hao, Long Li, Shipeng Zhang, Huanghua Zhang et al. (2023-12)
    The Synergistic Effect of Greenhouse Gas CO2 and Silica-Fume on the Properties of 3D Printed Mortar
  20. Liu Huawei, Liu Chao, Zhang Yamei, Bai Guoliang (2023-11)
    Bonding Properties Between 3D Printed Coarse Aggregate Concrete and Rebar Based on Interface Structural Characteristics
  21. Lyu Qifeng, Dai Pengfei, Chen Anguo (2023-10)
    Mechanical Strengths and Optical Properties of Translucent Concrete Manufactured by Mortar-Extrusion 3D Printing with Polymethyl-Methacrylate Fibers
  22. Lyu Qifeng, Dai Pengfei, Zong Meirong, Zhu Pinghua et al. (2023-10)
    Plant-Germination Ability and Mechanical Strength of 3D Printed Vegetation Concrete Bound with Cement and Soil
  23. Liu Yi, Wang Li, Yuan Qiang, Peng Jianwei (2023-09)
    Effect of Coarse Aggregate on Printability and Mechanical Properties of 3D Printed Concrete
  24. Li Te, Tier Laire (2023-09)
    Analysis of the Effect of Glass-Powder on the Printability of Cement-Based Materials for 3D Printing Using ImageJ
  25. Ghasemi Alireza, Naser Mohannad (2023-07)
    Tailoring 3D Printed Concrete Through Explainable Artificial Intelligence
  26. Liu Junli, Tran Jonathan, Nguyen Vuong, Gunasekara Chamila et al. (2023-06)
    3D Printing of Cementitious Mortar with Milled Recycled Carbon-Fibers:
    Influences of Filament Offset on Mechanical Properties
  27. Pietras Daniel, Zbyszyński Wojciech, Sadowski Tomasz (2023-06)
    A 3D Printing Method of Cement-Based FGM Composites Containing Granulated Cork, Polypropylene Fibers, and a Polyethylene Net Inter-Layer
  28. Lyu Qifeng, Dai Pengfei, Chen Anguo (2023-05)
    Sandwich-Structured Porous Concrete Manufactured by Mortar-Extrusion and Aggregate-Bed 3D Printing
  29. Liu Chao, Zhang Yamei, Banthia Nemkumar (2023-05)
    Unveiling Pore Formation and Its Influence on Micromechanical Property and Stress-Distribution of 3D Printed Foam-Concrete Modified with Hydroxypropyl-Methylcellulose and Silica-Fume
  30. Diniz Hugo, Martinelli Antônio, Cabral Kleber, Ferreira Ruan et al. (2023-01)
    Synergistic Effects of the Use of Metakaolin, Sand and Water on the Properties of Cementitious Composites for 3D Printing
  31. Li Mingyang, Weng Yiwei, Liu Zhixin, Zhang Dong et al. (2022-09)
    Optimizing of Chemical Admixtures for 3D Printable Cementitious Materials by Central Composite Design

BibTeX
@article{yu_sanj_du.2022.EoCMCoAB3CP,
  author            = "Shiwei Yu and Jay Gnananandan Sanjayan and Hongjian Du",
  title             = "Effects of Cement Mortar Characteristics on Aggregate-Bed 3D Concrete Printing",
  doi               = "10.1016/j.addma.2022.103024",
  year              = "2022",
  journal           = "Additive Manufacturing",
  volume            = "58",
}
Formatted Citation

S. Yu, J. G. Sanjayan and H. Du, “Effects of Cement Mortar Characteristics on Aggregate-Bed 3D Concrete Printing”, Additive Manufacturing, vol. 58, 2022, doi: 10.1016/j.addma.2022.103024.

Yu, Shiwei, Jay Gnananandan Sanjayan, and Hongjian Du. “Effects of Cement Mortar Characteristics on Aggregate-Bed 3D Concrete Printing”. Additive Manufacturing 58 (2022). https://doi.org/10.1016/j.addma.2022.103024.